1 / 25

LEAN Product Development (LPD)

LEAN Product Development (LPD). Itzhak Ben-Levy - LEAN Expert 972-523579166 itzhak@benlevy.co.il www.benlevy.co.il. October 2012. Lean Definition. " A systematic approach to identifying and eliminating Waste through continuous improvement ". Lean is about our people –

bonnie
Download Presentation

LEAN Product Development (LPD)

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. LEAN Product Development (LPD) ItzhakBen-Levy - LEAN Expert 972-523579166 itzhak@benlevy.co.il www.benlevy.co.il October2012

  2. Lean Definition "A systematic approach to identifying and eliminatingWaste through continuous improvement" Lean is about our people– Train them, Empower them, Trust them, Motivate them, Engage them

  3. The Development Problems • Long development cycle times • Many redevelopment cycles • High development costs • Long production cycle times • High production costs

  4. What is the best way to understand what is going on ? Everyone see togetherall the picture Each oneSeparately see Part of the picture In The Box Out Of The Box

  5. LEAN LEAN Manufacturing LEAN Product Development

  6. The main Principles Of Lean Product Development • Establish customer-defined value • Front-load the product development process • Create a level product development information flow • Organize to balance functional expertise and cross-functional integration • Align your project through simple visualcommunication

  7. IPT PRINCIPLES • Focus on a product • Multidisciplinary team • Co - location • Team working

  8. IPT Integrated Product Team Sam Dan Gil Ron Ronny IPT Leader Manufacturing Stress CUSTOMER Quality &System Safety Analysis Neb Production Bill Engineering SUPLIER Roth Bob

  9. LPD workshop PROJECT MANAGER LPD principle LPD TOOL TOOLSLEAN TO DO LIST FACILITATOR Just Do It! IPT

  10. Project : Team Leader: DATE : N° PROBLEM / ISSUE / OPPORTUNITY COUNTERMEASURE / EXPECTED RESULTS RESPONSIBLE START COMPLETE STATUS Workshop TO DO LIST

  11. Development plan workshop

  12. LPD Gates SRR – SYSTEM REQUIREMENT REVIEW DRR– DESIGN READINESS REVIEW PDR– PELIMINARY DESIGN REVIEW . CDR– CRITICAL DESIGN REVIEW. TRR –TESTS READINESS REVIEW TRDR– TEST RESULT DESIGN REVIEW PRR– PRODUCTION READINESS REVIEW FAI – FIRST ARTICLE INSPECTION

  13. The process Main milestones LEGENT FUNCTIONAL DEPARTMENTS Time – days / weeks / month ACTIVITIES

  14. Outcome of LPD workshop Reducing development lead time and cost by: • Templates for capturing new data and information • A focus on value creating activities • New insights into the development process • Real time reallocation and synchronization activities • Discover Unknown - unknown • Team identity and emotional commitment • Common language among team members • To do list identifying new corrective actions

  15. Value to the customer • Solving customer Problems • Exploiting Opportunities • The product should Look good • The Customer should Feel good

  16. QFD shorten cycle time by: • Understanding value to the customer • Exploiting customer needs • Deriving and consolidation of the requirements from customer needs • Prioritizing requirements • Allocating requirements to the project team

  17. ONCE PRICE=PROFIT + COST Determined by the corporate "by product" of the design What the customer pays

  18. NOW DTC - Design To Cost COST=PROFIT-PRICE Determined by the competitors Determined to the project manager Determined by the corporate

  19. How the engineer now how to design? Sub contracting riveting welding casting forging machining The cost target determined it

  20. Reduce requirements And cost Requirements (QFD) challenge Accept all Important delete Consider to delete Not important Implementation Cost (DTC) High Low

  21. Cost Reduction workshop Facilitator DFMA Tools Multidisciplinary Team Project manager Challenge the design • Requirements • Architecture • Technology • Assembly • Reuse • COTS • Standards • Symmetry • Tolerances • No. of Parts • Tests • Commonality

  22. How to integrate the production and procurement into development process Multidisciplinary Team The project manager should require a real cost status in each gate

  23. Suppliers costs reduction Supplier Engineering Costs drivers Requirements Priorities Requirements Reduction Cost Reduction

  24. "What's it in for me?" Project Manager • Shorten Time to Market • Reducing manufacturing costs • Reduction of problem solving meetings of the project. • The project team itself solves the most problems and takes its responsibilities without management involvement. • Information provided to management is more reliable and realistic with maximum transparency • Introduction of a culture that allows to deal with complex issues and find solutions agreed upon in a very short time.

More Related