Lean product development implementation
- 1. LEAN Product Development Implementation Itzhak Ben-Levy - LEAN Expert [email protected] www.benlevy.co.il August 2012 Itzhak Ben-Levy LEAN Expert © 1
- 2. The Traditional way It is Too many parts expensive Nobody gave me The target cost I cant assemble it The requirements were changed Itzhak Ben-Levy LEAN Expert © 2
- 3. The Development Problems • Long development cycle times • Many redevelopment cycles • High development costs • Long production cycle times • High production costs Itzhak Ben-Levy LEAN Expert © 3
- 4. LEAN LEAN Manufacturing LEAN Product Development Itzhak Ben-Levy LEAN Expert © 4
- 5. 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 visual communication Itzhak Ben-Levy LEAN Expert © 5
- 6. LPD workshop Itzhak Ben-Levy LEAN Expert © 6
- 7. Outcome of LPD workshop Reducing development production 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 of activities • Team identity and emotional commitment • Common language among team members • To do list identifying new corrective actions Itzhak Ben-Levy LEAN Expert © 7
- 8. Itzhak Ben-Levy LEAN Expert © 8
- 9. Value to the customer • Solving customer Problems • Exploiting Opportunities • The product should Look good • The Customer should Feel good 9 Itzhak Ben-Levy LEAN Expert © 9
- 10. QFD shorten cycle time by: 1. Understanding value to the customer 2. Exploiting customer needs 3. Deriving and consolidation of the requirements from customer needs 4. Prioritizing requirements 5. Allocating requirements to the project team 10 Itzhak Ben-Levy LEAN Expert © 10
- 11. NPI - New Product Introduction IPT METHODOLOGIES (Integrated Product IPT Leader - Project Manager Team) System Engineering QFD Logistics REUSE Production Engineering DFMA Contracting PROCESS MAPPING Customer PHASE DTC Strategic Suppliers Finance MAKE-BUY GATE Planning RISKS MITIGATION Customer Service ARO Design Readiness DRR MANAGEMENT PLAN RISKS PRODUCTION & SPEC REQUIREMENTS CONFIGURATION DEVELOPMENT POLICY TECHNOLOGIES DEVELOPMENT PROTOTYPE PROGRAM PURCHASING PERFORMANCE MATERIAL RESOURCES TIME TABLES ARCHITECTURE ENVIRONMENT COMPONENTS MANPOWER ORGANIZATION CHART REUSE INFRASTRUCTURE BUDGET PLAN TESTS MAKE-BUY TARGET COSTS CUSTOMER QUALITY ILS SUB CONTRACTORS DEVELOPMENT REQUIREMENTS PRODUCTION CUSTOMER DELIVERIES MAINTAINABILITY LCC PRODUCT TESTS OUTPUTS DEVELOPMENT TOOLS Itzhak Ben-Levy LEAN Expert © 11
- 12. LPD Gates 1. SRR – SYSTEM REQUIREMENT REVIEW 2. DRR – DESIGN READINESS REVIEW 3. PDR – PELIMINARY DESIGN REVIEW. 4. CDR –CRITICAL DESIGN REVIEW. 5. TRR– TESTS READINESS REVIEW 6. TRDR– TEST RESULT DESIGN REVIEW 7. PRR– PRODUCTION READINESS REVIEW 8. FAI – FIRST ARTICLE INSPECTION Itzhak Ben-Levy LEAN Expert © 12
- 13. DTC PRICE - PROFIT = COST Determined by the competitors Determined Determined by the to the project corporate manager Itzhak Ben-Levy LEAN Expert © 13
- 14. How the engineer now how ?to design Sub contracting riveting casting welding forging machining The cost target determined it Itzhak Ben-Levy LEAN Expert © 14
- 15. Reduce requirements And cost Requirements (QFD) challenge Accept all Important Consider to delete Not delete Implementation important Cost High (DTC) Low Itzhak Ben-Levy LEAN Expert © 15
- 16. Suppliers costs reduction Supplier Engineering Costs drivers Requirements Priorities Cost Reduction Requirements Reduction Itzhak Ben-Levy LEAN Expert © 16