Lean Design - Lean Product Development Workshop Description

Overview –

Despite an increasing need for speed and efficiency, much of the effort expended by product development teams is often unnecessary and potentially wasteful. In many cases, only one hour in eight of team members' time is spent directly creating value for their customers. The Lean Product Development Workshop presents a set of leading-edge, practical tools for slashing waste and increasing speed and efficiency. The “lean methods” described in this course enable dramatic reductions in time-to-market while freeing up valuable resources for additional project work. Firms that have embraced these practical, waste-eliminating tools have reported up to fifty-percent reduction in launch schedules, significant improvements in gross margin, and enhanced customer satisfaction. This hands-on workshop covers all aspects of the subject, including a step-by-step process for customizing your own lean process that will enable rapid, high-value product development.

Upon Completing this Course, Students Should Be Able to –

1. Identify non-value-added tasks and wasteful work habits on any development project.
2. Apply twelve lean methods that provide immediate savings of time and cost.
3. Use a step-by-step method for prioritizing improvement activities.
4. Improve the quality and efficiency of customer / team / management communication.
5. Maximize the utilization of scarce human and capital resources.
6. Support a culture of discipline, value focus, and intolerance of waste.

Who Should Attend -

Product-line managers, team leaders, task managers, functional managers, six-sigma blackbelts / greenbelts, improvement champions, operations managers, process owners, design engineers, and all others with product development responsibilities.

Workshop Outline –

Note: A series of practical workshop exercises accompanies the following lecture agenda, including value-stream mapping of real-life development projects, and brainstorming on ways to immediately eliminate non-value-added waste. The output of the workshop is a prioritized action list for immediate improvement.This workshop uses Building a Project-Driven Enterprise, by Ron Mascitelli, as its textbook.

Part I. How You Will Benefit
• Typical sources of waste in product development
• A common-sense, toolbox approach

Part II. A Brief “Lean Thinking” Tutorial
     • How the five principles of lean thinking apply to new product development
     • Avoiding undershoot and overshoot of customer needs
     • Exception management, and other fundamental concepts
     • The “Continuous Flow” development process

Part III. A Toolbox for Speed and Efficiency
     • Method #1 – Testing for Customer Value
          o The Kano Model
          o Must / Should / Could Prioritization
          o The Lean QFD
     • Method #2 – Linked Tasks and the Deliverables Roadmap
          o Forming Linked Tasks
          o The Deliverables Roadmap
          o Eliminating Approval Delays
          o E-mail “rules” for waste elimination
     • Method #3 – Time Slicing and Stand-up Meetings
          o Setting aside “project time”
          o Managing entire projects on ten minutes a day
          o The visual project board
          o Managing the turbulence of sustaining support / customer emergencies
          o Expediting the decision process
     • Method #4 – Project Data Management
          o Projects Intranet Site
          o The Wall Gantt
          o PDM Software
     • Method #5 – The “Waste-Free” Design Review
     • Method #6 – Staged-Freeze Specifications
          o How to Control Invasive Change
          o Major / Minor Freeze Points
          o Informal Change Control
     • Method #7 – Value Stream Mapping for Waste Elimination
          o Identifying Waste and Value
          o Prioritizing Improvement Opportunities
          o Current State / Future State Mapping
     • Method #8 – Standard Work Methods and Templates
          o Work Rules
          o Checklists
          o Templates and Guidelines
     • Method #9 – Risk Buffering and Value Increments
          o Objective Tracking of Project Progress
          o Incremental Value Milestones
          o Protecting Deadlines with Risk Buffers
     • Method #10 – Resource Prioritization and “Superteams”
          o Identifying Resource Constraints (Bottlenecks)
          o Active Management of Resource Constraints
          o Avoiding Excessive Multitasking
          o Resource Management via Superteams
     • Method #11 – Lean Supplier Management
     • Method #12 – Lean Self-Assessment and Kaizen Tools
          o The Lean Self-Assessment Quiz
          o A “Mini-Kaizen” to Establish Prioritized Actions

Part IV. Strategies for Successful Deployment