The document outlines key concepts of lean design and the Toyota product development system. It discusses the lean design process which includes 6 phases from concept to production. It identifies types of waste in product development like defects, excess inventory, unnecessary processing. The document also notes issues around long cycle times, cost, and quality in traditional design and how lean principles can help address these.

1. Superfactory ® Lean Enterprise Series Lean & Six Sigma Design

3. Lean Design & Six Sigma Phase 2 Concept Phase 1 Pre-concept Phase 3 Product Definition Phase 4 Detailed Design Phase 5 Integration & Test Validation Phase 6 Production & Operation CUSTOMER C T Q ’ S B U S I N E S S C T Q ’ S T E C H N I C A L C T Q ’ S T E C H N I C A L R E Q U I R E M E N T S L I S T Manufacturing Process Control Design for Six Sigma Product Development Process Lean Design Supplier Rationalization Quality Improvement Cycle Time and Cost Improvement

7. Cycle Time Issues Excessive Product Development Cycle Time 11 Months on Average Why ? Rework Loops From Detailed Design Starting Before Product Reqs. Are Defined Detailed Design Takes Too Long Requirements Capture & Lockdown Takes Too Long Why ? Why ? No Process for Requirements Capture Lack Reqs. Lockdown Discipline Lack Similar to Product Capabilities Capable Resources not Available Redesign Rather than Reuse Capable Products Supplier Selection Time Delay (6 weeks) Long Lead Time Parts Procurement Delay (12weeks) Why ? Why ?