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Lean Product Development
Time Commitment5 days
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Optimize your innovative potential with Lean Product Development.
Learn essential strategies and key tools that will decrease time-to-market, reduce waste, enhance product quality, and fully integrate new product designs into a Lean production environment. Leave prepared to bring your best ideas to market as effectively and quickly as possible.
- Learn about the Lean product development process and the tools of the Toyota Development System
- Apply value stream mapping techniques to product and process development
- Create an implementation plan for your organization
- Develop systematic error proofing processes
- Acquire tools for effectively launching your new product or process
- Consider the roles of organizational culture and the challenges of leading Lean change
Mon-Fri 8:00AM – 4:30PM ET
LAPTOP REQUIRED FOR IN-PERSON OFFERINGS
- Impact and benefits of Lean PD
- Overview of Lean PD principles
- Lean Product Development simulation – Round #1 (traditional PD)
- Problems with traditional product development
- Illustration of typical wastes
- Tracking metrics associated with traditional wastes
- Driving flow in product development: insights from queuing theory
- Kentou phase
- Decision flow mapping
- Learning cycles
- Set-based concurrent engineering
- Intro to people systems
- Balance functional expertise with cross-functional integration
- Develop towering technical competence in all engineers
- Chief Engineer system – abridged version; focus on concept paper/VOC
- Supplier partnerships
- Tools for organizational learning and continuous improvement
- Overview of learning tools and techniques
- Checklists and matrices
- Tools for communication and alignment
- Hoshin management overview
- A3 reports overview – 4 types
- Differences between manufacturing and product development value streams
- VSM icons for product development
- Current state map building blocks
- Build a current state map
- Identifying waste in the current state map
- Build future state map
- Applying A3 thinking and problem solving to real-life challenges you are facing at work
- Define the problem – elements of a good problem statement
- Setting clear goals
- Root cause analysis – overview of techniques
- Countermeasures – short and long term
- Implementation plan
- Follow up – the critical “check” and “act/adjust” phase of PDCA
- Case study & applications
- Case studies of applying Lean PD techniques
- Lean PD implementation approaches & lessons learned
- Summary of Lean PD principles
- Cultural characteristics of Lean PD
- Simulation Round #2 (Lean)
- Apply Lean principles from class to the simulation
- Illustrate the impacts on a PD system
- Implementation approaches to drive Lean principles in your organization
- How to get started
- Lessons learned – what works and does not
- Implementation examples from selected companies
- Getting started – A3 proposal for your first steps on the Lean PD journey
WHO SHOULD ATTEND
This course is intended to benefit professionals involved in:
- Product planning
- Product design and development
- Process development
- Product and process validation
- Manufacturing or product launch
John Drogosz, PhD
- Lean Specialist and Instructor, Nexus, College of Engineering
- Vice President, Optiprise Inc.
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