Product Development (Knowledge) Wastes
(Based on Lean Product and Process Development by Allen C. Ward, The Lean Enterprise Institute, March 2007)
Scatter Communication Barriers Physical Barriers – Distance, location, incompatible computer formats
Actions that make knowledge Right knowledge, to the right Social Barriers – Corporate “Class Systems”, management behaviors (NIH, shooting
ineffective by disrupting flow. place, at the right time. messenger, etc.)
Skill Barriers Not knowing how to turn data into useful knowledge
The right knowledge doesn’t get to
the right place Information Channels – multiple late and conflicting copies of the same data.
Reorganization – obsoletes
interaction knowledge Poor Tools Over specification of APD tasks.
Workload variation adding resources Written procedures that require Cut Corners – checking off tasks rather than using them to develop knowledge.
– disrupts communication (use developers to use inefficient More cross checks, reports and tasks – Overwhelmed developers
Support resources slow – Harassment
bogs down super system. Find and fix
Handoff Useless Information Eliminate or replace information demand.
The most critical waste. Doesn’t help understand Introduce new management concepts and systems to really do what the reports were
Separation of knowledge, customer, integration, supposed to do (FMEA’s – design to eliminate failure)
responsibility, action, and feedback. innovation or promote good
The people making decisions don’t decisions.
have the required knowledge Because someone wants it.
Hand‐off implies 70‐90% of the
information is lost in transfer. Waiting Hard sequential milestones.
Avoid “Push” task planning & scheduling – Look at project planning from a “Pull”
Wishful Thinking Testing to Specifications Freezing specifications too early
Making decisions without data or Cannot test your way to quality – Test to ID failure points and design to eliminate them.
operating blindly. Pass/Fail mindset
Locking in on a single concept prior to Employ Process Control not Product Control
Murphy is dead, the moon and stars Discarded Knowledge “Getting the product out!” ignores creating the operational value stream.
will align, and a miracle will happen. Failure to put project Data contains no knowledge until analyzed.
“knowledge” into a useable Train engineers how to generate data with the potential to develop useful knowledge.
form. Train engineers how to transform data into useful knowledge
Capture knowledge in an effective and efficient manner so that It can be retrieved for
What fraction of an engineer’s time is spent locating knowledge that has already been
developed at least once?