Lean Product
Development™
The following is a
brief summary of Lean Product
Development or Lean DFSS (LDFSS) training and consulting available from
SBTI.
For details on the
following points download the Lean
Product Development White Paper below.
For Design for Six
Sigma (DFSS) without the Lean
elements, click
here.
If you have
questions on how to deploy Lean Product
Development, please click on Lean
Product Development Information
for further details.
What is Lean
Product Development™?
(LDFSS)
The Lean Product Development for Six Sigma or Lean DFSS training
methodology can be considered a second generation of the widely adopted
Design
For Six Sigma . The simplified
notion is to design quality and
"leanness" into the product before it ever gets to the manufacturing
floor where Lean/Six Sigma Black Belts are working. In the ideal world
Lean Product Development™ Black Belts put Lean/Six Sigma
Black
Belts to work on only
manufacturing problems with no
design related problems being "solved" once production begins. Lean
Product Development™ Black Belts often work side-by-side with
their Lean/Six Sigma counterparts, using their expert knowledge to
solve process problems even before they happen. Included in Lean
Product Development are the Six Sigma Tools, DFSS tools, and Lean
Manufacturing tools and concepts that can be used by engineers working
on new designs.
How does Lean
Product Development™ differ from Six
Sigma or Lean-Sigma?
Lean Sigma and Six Sigma target
manufacturing and other
business processes, whereas the Lean Product Development™
methodology focuses within the product development on a particular
product. Lean / Sigma Black Belts are taken from their existing
functions to become a "fire-brigade", tackling problem processes. Lean
Product Development™ belts tend to remain within their
functions
applying a stronger toolkit and design problem solving methodology.
Benefits of
undertaking Lean Product
Development™ training come from the following:
- Improved quality
at product launch, because the
product is more tolerant to variation in both the supplied components
and the manufacturing process itself and has fewer raw material
components
- Faster
development time
- Increased
revenue due to the product being perceived
of higher value by the customer
- Reduced
inventory costs due to fewer components and
more re-use of components across products i.e. fewer unique parts
- Reduced assembly
times because the product has fewer
components and those that it does have are easier to manufacture
- Reduced product
cost by better selection of material
and manufacturing process
Program
Overview
- Business Case
(understanding the market)
- Concept
Development (understanding the customer)
- Lean Concepts
- Platform /
System Architecture
- Introduction to
Statistics
- Understanding
manufacturing
- Product Design
for manufacturability
- Optimizing the
product
- Moving to
capable manufacturing
There
are 5 levels of attendance to the Lean
Product Development™ training course:
- Executive -
attends 1 day of training at the launch
of initiative to understand Lean Product Development™
concepts
and philosophy, and how to drive it in the business. Typical attendees
are the executives and senior business leaders.
- Champion -
attends 3 days of training prior to first
week to learn what to expect of their Black / Green Belt(s) and how
best to support them. Typical attendees are the managers of the
initiative and Black Belt / Green Belt mentors.
- Black Belt -
attends all 5 weeks of training and is
required to complete a project. Typical attendees are the project team
leaders.
- Green Belt -
attends all of the first 3 weeks of
training. A Green Belt learns to an intermediate level of the Lean
Product Development™ Design curriculum and is required to
complete a project. Typical attendees are the project team members.
- Week 1 - attends
the whole of the first week of
training to understand the concepts central to the Lean Product
Development™ philosophy along with tools to
strengthen the
early stages of the NPI process. Typical attendees are members of the
project teams and anyone in the company affected by the projects.
Expert
Lean Product Development Consulting is
available to SBTI customers in the following areas:
- New Product
Development (NPD) - If you need expert
consulting in any stage of development for a new product, be it
concept, design, optimization or launch, SBTI can help.
- NPD or Stage
Gate Process Assessment - If your new
product development process or pipeline is not working as it should, we
can do an NPD assessment over several days with precise feedback about
what needs to change and why.
- Specific tools
implementation and consulting - Be it
Kano Analysis, KJ, Pugh Concept or Design for Assembly, SBTI has world
class Lean Product Development consulting available to help your design
teams succeed.
Please click on Lean
Product Development Information
for further details.
Click Here to download the .pdf
white paper on
Lean Product Development ™ (Lean DFSS) !
 245k
LDFSS
Links
Software
DFSS with PS&J
Service &
Process Design (SSPD or Transactional DFSS)
Critical
Parameter Management Software for LDFSS (Cognition)
LDFSS Enterprise
Project Management:
Instantis,
PowerSteering
Monte
Carlo Simulation(Crystal Ball),
Process Simulation with IGrafx
LDFSS Tools
& Methods Software:
Modular Design Examples ,
QFD
& TRIZ with IdeaCore,
Reliability
Tools by Relex,
Tolerance
Modeling with VarTran
Lean Product
Development Related Societies & Meeting
Places:
Product
Development and Management Association,
The
Lean Construction Institute,
The
Lean Enterprise Institute,
ISixSigma,
IEEE,
ASME,
Society
of Reliability Engineers,
ISSSP
Six
Sigma Forum
Other Useful Links
and Information:
Engineering Statistics Handbook
The
Patent Cafe
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