Lean Management Methods in Product Development – A Case Study

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Lean Management Methods in Product Development – A Case Study

Advances in Sustainable and Competitive Manufacturing Systems
Lecture Notes in Mechanical Engineering 2013, pp 1385-1399.
23rd International Conference on Flexible Automation & Intelligent Manufacturing (FAIM 2013)

http://link.springer.com/chapter/10.1007%2F978-3-319-00557-7_112

Daniel Soares 1, João Bastos 2,3, Diana Gavazzo 1, João Paulo Pereira 1 and A.J. Baptista 1

1 INEGI – Instituto de Engenharia Mecânica e Gestão Industrial Faculdade de Engenharia da Universidade do Porto Porto, Portugal
2 INESC TEC Faculdade de Engenharia da Universidade do Porto Porto, Portugal
3 ISEP Instituto Superior de Engenharia do Instituto Politécnico do Porto Porto, Portugal

ABSTRACT
The current reality of intense competition has forced many companies to increase their performance and competitive advantages by pursuing innovation and improving and streamlining internal methods of designing products and processes. With shortening of product life cycle, in order for companies to survive, the need for a continuous stream of multiple innovations over time has arisen. However, the resources consumed by companies, whilst developing a product or process, are increasingly high, even in integrated approaches, and often the finished product or process arrives too late to provide the company with an edge over its competitors. Due to the large impact Lean philosophy has had in recent decades, within the manufacturing area, through the increase of efficiency and generation of continuous improvement, more companies have progressively applied Lean methods in their units of product and process development. This paper seeks to present a reference model for Lean implementation in the areas of product and process development in order to support companies in their path to streamline and make their innovative processes more efficient. The proposed reference model includes a concrete case study example that helps to explain the main concepts behind the proposed approach.

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Lean Management Methods in Product Development – A Case Study

  1. 1. ThechallengeofSustainingGlobalCompetitiveManufacturingSystems Daniel Soares1, João Bastos2,3, Diana Gavazzo1, João Paulo Pereira1 and A.J. Baptista1 Lean Management Methods in Product Development – A Case Study 1 INEGI – Instituto de Engenharia Mecânica e Gestão Industrial 2 INESC TEC – Instituto de Engenharia de Sistemas e Computadores do Porto 3 ISEP – Instituto Superior de Engenharia do Porto
  2. 2. ThechallengeofSustainingGlobalCompetitiveManufacturingSystems Porto,Portugal CONTENTS 1. Introduction 2. Lean manufacturing vs Lean product development 3. Reference model development 4. The “stopper” concept in the PDCA cycle 5. Implementation examples 6. Results and final considerations Lean Management Methods in Product Development A Case Study
  3. 3. ThechallengeofSustainingGlobalCompetitiveManufacturingSystems Porto,Portugal 1. Introduction Top Management Commitment Lean Management Methods in Product Development A Case Study Difficulties of Lean Implementations and Continuous Improvement The (common) human resistance to change “Making Change Work: Practical Tools for Overcoming Human Resistance to Change” Book by Brien Palmer ? ? ? ??
  4. 4. ThechallengeofSustainingGlobalCompetitiveManufacturingSystems Porto,Portugal 1. Introduction Lean Management Methods in Product Development A Case Study Difficulties of Lean Implementations and Continuous Improvement Have an accurate assessment of the “AS IS” (initial) state Visible components of the system Processes Procedures Tools Invisible components of the system Culture Behaviours Mentality Habits
  5. 5. ThechallengeofSustainingGlobalCompetitiveManufacturingSystems Porto,Portugal 2. Lean manufacturing vs lean product development Lean Management Methods in Product Development A Case Study Manufacturing Visible flux of materials and WIP Easier identification of wastes (stocks, WIP, disorganization, bottlenecks, failures, etc.) Repeatable tasks and processes Product Development Invisible flux of data and information More difficult to identify waste (over-engineering, poor knowledge management, slow access to information, etc.) Strong process variability (less repetitive tasks) Ability to influence teams productivity and the customer defined value and costsAbility to influence product quality, operation costs and productivity
  6. 6. ThechallengeofSustainingGlobalCompetitiveManufacturingSystems Porto,Portugal 3. Reference model development Lean Management Methods in Product Development A Case Study Culture of the organization Supportive Management Improved Quality – Reduced Cost Reduced Lead Time – Improved Security – High Morale Lean Management Respectfor Humanity Continuous Improvement Information flows • Clear • Accurate • At the right time Value
  7. 7. ThechallengeofSustainingGlobalCompetitiveManufacturingSystems Porto,Portugal 4. The “stopper” concept in the PDCA cycle Time Improvement Standardization stable levels (classic lean approach) Lean Management Methods in Product Development A Case Study An “anti-rollback mechanism” during change transition Objectives Analyse failure modes or weaknesses for the process improvement implementation Find intrinsic motivation within the team for the change Avoid unpredicted issues for the change before it happens Secure the improvement progress until the complete standardization stable level Change transition
  8. 8. ThechallengeofSustainingGlobalCompetitiveManufacturingSystems Porto,Portugal 5. Implementation examples Lean Management Methods in Product Development A Case Study Respect for Humanity: Skills and intrinsic motivation matrix
  9. 9. ThechallengeofSustainingGlobalCompetitiveManufacturingSystems Porto,Portugal 5. Implementation examples Lean Management Methods in Product Development A Case Study Respect for Humanity: Skills and intrinsic motivation matrix Objectives Get a information about each team member Skills (Self Evaluation) and hidden talents Get a information about each team member intrinsic motivation (Self Evaluation) Match adequate team member skills for the project and which he/she is more motivated for those technical areas Detect insufficient technical capabilities within the team Manage team knowledge more effectively both for projects and training
  10. 10. ThechallengeofSustainingGlobalCompetitiveManufacturingSystems Porto,Portugal 5. Implementation examples Lean Management Methods in Product Development A Case Study Overcoming information access issues and time waste burden Problems Get to know for the entire team useful and essential information (technical or general) Avoid long time waste searching information and long clicking sequences Avoid resistance and blocking attitudes for folder directory re- organization by 5S tool application Objectives Aggregate and compile information at “one click distance” Create a visible link for a digital box of suggestions and issues reporting Create an robust and simple method to change file folder systems organization without impact normal day work
  11. 11. ThechallengeofSustainingGlobalCompetitiveManufacturingSystems Porto,Portugal 5. Implementation examples SF3 SF2 SF1 Main Folder Lean Management Methods in Product Development A Case Study Overcoming information access issues and time waste burden SubFolder 1 SubFolder 2 SubFolder 3 Target File Target File Spaghetti line length - elapsed time Main Folder
  12. 12. ThechallengeofSustainingGlobalCompetitiveManufacturingSystems Porto,Portugal 5. Implementation examples SF3 SF2 SF1 Main Folder Lean Management Methods in Product Development A Case Study Overcoming information access issues and time waste burden SubFolder 1 SubFolder 2 SubFolder 3 Target File Target File Ideal Solution = Direct way Main Folder
  13. 13. ThechallengeofSustainingGlobalCompetitiveManufacturingSystems Porto,Portugal 5. Implementation examples Lean Management Methods in Product Development A Case Study Overcoming information access issues and time waste burden “Real world inspiration”: temporary bridge
  14. 14. ThechallengeofSustainingGlobalCompetitiveManufacturingSystems Porto,Portugal 5. Implementation examples Lean Management Methods in Product Development A Case Study Overcoming information access issues and time waste burden “Digital inspiration” Invisible meta data linked to organized visible icons
  15. 15. ThechallengeofSustainingGlobalCompetitiveManufacturingSystems Porto,Portugal 5. Implementation examples Lean Management Methods in Product Development A Case Study Overcoming information access issues and time waste burden Stoppers: Use of wide spread Power Point software and attractive features for the team (both technical and for social team integration)
  16. 16. ThechallengeofSustainingGlobalCompetitiveManufacturingSystems Porto,Portugal 5. Implementation examples Lean Management Methods in Product Development A Case Study Overcoming information access issues and time waste burden
  17. 17. ThechallengeofSustainingGlobalCompetitiveManufacturingSystems Porto,Portugal 5. Implementation examples Lean Management Methods in Product Development A Case Study Other issues and implemented solutions Standardized Project Folder Structure (reduced time for new project members) Standardized file name convention Technical Library re-organization (with Endnote, more than 1000 files catalogued) List of contacts (team members, clients, suppliers) List of suppliers capabilities and evaluation by technical areas Development of advanced timesheets for time and task control
  18. 18. ThechallengeofSustainingGlobalCompetitiveManufacturingSystems Porto,Portugal 6. Results and final considerations Lean Management Methods in Product Development A Case Study Development of an adapted Reference Model for Lean Implementations in Product Development Projects Development of conceptual strategies for dealing with the change process Lean thinking and continuous improvement introduction within the team Centralization and broad availability and awareness of essential and useful information for the team Standardization of name convention for files and folders (documental management) Identifying team technical skills weakness, hidden talents and knowledge level Increased motivation of team members by knowing and using their intrinsic motivations and opinion (suggestions and issues reporting) Estimated gains of 2300 hours / annum (within a 15 elements group)
  19. 19. ThechallengeofSustainingGlobalCompetitiveManufacturingSystems Daniel Soares1, João Bastos2,3, Diana Gavazzo1, João Paulo Pereira1 and A.J. Baptista1 [abaptista@inegi.up.pt] Lean Management Methods in Product Development – A Case Study

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