Accelerated Product Development Workshop Outline

Lean Overview

• Opportunities for improving the product development process
• The complementary nature of Lean and Six Sigma
• Lean fundamentals and concepts
  • Concept of value-added
  • Waste
  • Flow
  • Push versus pull systems
  • 5S

Lean Principles for Product Development

• Review of the five factory-based Lean principles
• Product development characteristics to leverage for Lean implementation
• Lean principles for product development

Baseline Analysis for Product Development

• Objectives and purpose of conducting a baseline event
• Elements of organization, planning, and logistics for conducting a baseline event
• Structure of discovery teams for conducting a baseline event - specifically for product development
  • Mission of each team
  • Data requirements

Resource and Workload Management

• Issues that contribute to the problem of resource and workload management
• Strategies to improve resource and workload management
  • Match work demand to resource capacity
  • Concentrate the work by minimizing multitasking, hand-offs, and starting and stopping work
• Implementation of a resource and workload management process
  • Pipeline demand and capacity management
  • Work management process

Reuse Concepts

• The philosophy of reuse
  • Reuse rules
  • Understanding the impact of a new part
• Implementing a reuse strategy for product development
  • Preferred parts
  • The process for part design reuse
  • Measuring reuse
  • Initial implementation: Commodity parts consolidation in the factory

Process Infrastructure

• Infrastructure needed to support the product development process
  • Design assurance
  • Project management
  • Resource management
• Process requirements
  • Objectives
  • Organizational structure and responsibilities
  • Process reviews
  • Typical process metrics

The Design Process

• Key issues that influence design strategy selection
• Modular, platform, and custom design strategies
  • Tools
  • Benefits and characteristics of each approach

Knowledge Management

• Fundamentals of knowledge management
  • What is knowledge management?
  • Types of knowledge
• Key steps to implement effective knowledge management
• The role of KM tools
  • Tool examples
  • Key features and functionality

Manufacturing and Supply Chain Integration

• Importance of the supply chain in meeting the company’s goals for reducing product development cycle time and cost
• An integrated strategy that yields significant reductions in part cost and procurement lead time
• Case study example that highlights the benefits of an integrated product development and supply chain strategy

Manufacturing Process Control

• Concepts of Six Sigma and Manufacturing Process Control (MPC)
  • The impact of variation
  • Benefits
  • The role of data
• The process for implementing MPC
  • The role of key characteristics
  • Using scorecards for analyzing data
  • Implementing a control plan
• Tips for implementing MPC with suppliers

Design for Six Sigma

• Objectives of Design for Six Sigma (DFSS)
  • The importance of DFSS
  • The approach for DFSS implementation
• Elements of DFSS
  • Performance element
  • Manufacturing element
  • Reliability element
  • Process capability models and their role in supporting DFSS

Flow and Cell Design for Non-Factory Processes

• The concept of flow
  • Determining the appropriate time to implement flow
  • Takt time
  • Line Balancing
• Contrasting the characteristics of traditional office work versus a cellular approach
• The 8-step model for creating a cell for an existing work process