Wednesday, March 11, 2015

Lean Product Development - Low Waste Product Development - Efficient Product Development

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Some Differences between Lean Product Development and Functional Product Development

Lean              -         Functional Product Development
Lean Thinking    -             Functional Management
Rapid Model Replacement  -  Slow model replacement
Frequent model-line expansion - Infrequent model line expansion
More incremental product improvements - More radical product improvements
Heavyweight project managers  -  Lightweight project coordinators
Overlapping compressed phases  - Sequential long phases
High levels of supplier engineering  - High levels of in-house engineering
Design team and project-manager continuity -  Department member continuity
Good communication mechanisms  - Walls between departments
Cross-functional teams  -     Narrow skills in specialized departments

Seven Waste Model Application to Product Development

The Lean Aerospace Initiative (LAI) Product Development Team applied the seven wastes model to product development.

Source: Warmkessel, J. (1998). Introduction to the Product Value Stream. Cambridge, MA.

• Over Production

• Too Much Detail
• Unnecessary Information
• Redundant Development(Reuse
not practiced)

• Transportation

• Information/Software
• Communications Failure
• Not Standards Based
• Multiple Sources
• Incompatible destinations requiring multiple transport

• Waiting

• Information Created Too Early
• Late Delivery of Information
• Unavailable Information
• Quality Suspect

• Processing

• Unnecessary Serial Processing
• Lack of Needed Information
• Poor/Bad decisions affecting
• Excess/Custom Processing
• Not processed per process
• Too Many Iterations/Cycles
• Unnecessary Data Conversions
• Excessive Verification
• No Transformation Instructions
• Decision Criteria Unclear
• Working WithWrong Level of Detail
• Propagation of Bad Decisions
• Processing of Defective Information
• Multiple Tasking When Not Required

• Inventory

• Too Much Information
• Incomplete Content
• Poor Configuration Management

• Unnecessary Movement

• Information User Not Connected
to Sources Requiring Manual
• Information Pushed to Wrong

• Defective Product

• Quality Lacking or Suspect
• Conversion Error
• Wrong Level of Information
• Incomplete Information
• Ambiguous Information
• Inaccurate Information
• Tolerance Exceeded
• Poor Configuration Management

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