Lean product development implementation

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Simple tools how to implement lean product development

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Lean product development implementation

  1. 1. LEAN Product Development Implementation Itzhak Ben-Levy - LEAN Expert itzhak@benlevy.co.il www.benlevy.co.il August 2012Itzhak Ben-Levy LEAN Expert © 1
  2. 2. The Traditional way It is Too many parts expensive Nobody gave me The target cost I cant assemble it The requirements were changedItzhak Ben-Levy LEAN Expert © 2
  3. 3. The Development Problems • Long development cycle times • Many redevelopment cycles • High development costs • Long production cycle times • High production costsItzhak Ben-Levy LEAN Expert © 3
  4. 4. LEANLEAN Manufacturing LEAN Product DevelopmentItzhak Ben-Levy LEAN Expert © 4
  5. 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 communicationItzhak Ben-Levy LEAN Expert © 5
  6. 6. LPD workshopItzhak Ben-Levy LEAN Expert © 6
  7. 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 actionsItzhak Ben-Levy LEAN Expert © 7
  8. 8. Itzhak Ben-Levy LEAN Expert © 8
  9. 9. Value to the customer • Solving customer Problems • Exploiting Opportunities • The product should Look good • The Customer should Feel good 9Itzhak Ben-Levy LEAN Expert © 9
  10. 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 10Itzhak Ben-Levy LEAN Expert © 10
  11. 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 TOOLSItzhak Ben-Levy LEAN Expert © 11
  12. 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 INSPECTIONItzhak Ben-Levy LEAN Expert © 12
  13. 13. DTC PRICE - PROFIT = COST Determined by the competitors Determined Determined by the to the project corporate managerItzhak Ben-Levy LEAN Expert © 13
  14. 14. How the engineer now how ?to design Sub contracting riveting casting welding forging machining The cost target determined itItzhak Ben-Levy LEAN Expert © 14
  15. 15. Reduce requirements And cost Requirements (QFD) challenge Accept all Important Consider to delete Not delete Implementation important Cost High (DTC) LowItzhak Ben-Levy LEAN Expert © 15
  16. 16. Suppliers costs reduction Supplier Engineering Costs drivers Requirements PrioritiesCost Reduction Requirements ReductionItzhak Ben-Levy LEAN Expert © 16

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