1. INTRODUCTION
- The Five Lean Thinking Principles
- Define Value to the Customer
- Identify the Value Stream and Eliminate Waste
- Make the Value-Creating Steps Flow
- Empower the Team
- Learn and Improve
- Lean Design - Maximize Customer Value with a Minimum of Resources
- The 13 Practices of Lean Design
2. DETERMINE WHAT CUSTOMERS VALUE
- Voice of the Customer
- Developing Customer Focus as a Basis for Maximizing Customer Value
- Starting Point: Understanding the Voice of the Customer
- The Kano Model
- Methods for Voice of the Customer Investigation
- Digging Deeper than Stated Customer Needs with Observation
- Determining the Value of Customer Needs with Conjoint Analysis
- Organizing and Distilling Customer Needs with Affinity Diagramming
and Customer FAST Diagrams
3. MAXIMIZING CUSTOMER VALUE IN PLANNING PRODUCT REQUIREMENTS
- Requirements are the Ultimate Cost Driver
- Start with the Customer Value Proposition
- Conjoint Analysis - Determine What is of Value
to the Customer
- Planning Products with Quality Function Deployment (QFD) to
Assure a Correct Focus on Customer Needs
- Competitive Analysis: Developing the Product Strategy and the Customer Value Proposition
- Translating Customer Needs into Technical Characteristics or Product Requirements
- Maximize the Value Proposition - Avoid Unnecessary/Low
Priority Functions, Features and Capabilities
- Making Tradeoffs to Maximize Customer Value
- Using Quality Function Deployment to Balance Requirements, Specification Values and Cost
- Using Quality Function Deployment to Understand Cost Drivers
- Customer Function Diagram to Abstract Requirements and Assess Completeness
4. ESTABLISHING A TARGET COST
- Establishing a Market-Driven Target Price or Price-to-Win
- Determining Supply Chain Margins, Distribution Costs, Warranty
Costs, Corporate Allocations & Profit
- Determining a Target Cost From the Target Price
- Target Cost Worksheet & Example
- Allocating & Tracking Target Costs
- Using Product Cost Models and Cost Tables to Track
Target Costs/Design to Cost Achievement
- Basic Product Cost Models - BOM Cost Roll-ups and Spreadsheets
- Creating and Refining a Predictive Cost Model
- Commercial Cost Model Tools
- Validating Cost Projections
- Cost Tracking and Performance Monitoring
- Life Cycle Cost Costs & Cost Models
5. EMPOWERED CROSS-FUNCTIONAL TEAMS: KEY FOR LEAN DESIGN
- Why Cross Functional Teams?
- Relationship to Functional Management vs. Program Management
- Steps to Create Effective Cross-Functional Teams
- Importance of Collocation or Virtual Collocation
- Exercise: Cross-Functional Team
- Empowering Teams for Lean Product Design
- What Does Empowerment Mean?
- Pushing Down Decision-Making to Lowest Effective Level
- Going Beyond Assignment to Adequate Involvement
- Impact of Experience and Skill Level on Team Effectiveness
6. LEAN DESIGN ACTIONS DURING CONCEPT DEVELOPMENT
- Use of Function Analysis to Explore Concept Requirements and Reduce
Costs
- Value Engineering & the Function Analysis/Value Analysis
Methodology
- Function Analysis Exercise I
- Function Cost Matrix & Value Analysis Matrix
- Function Analysis System Technique (FAST)
- Function Analysis Exercise II
- Importance of Exploring Concept Alternatives
- Brainstorming and Other Creativity Techniques
- TRIZ and Theory of Inventive Problem Solving
- Concept Evaluation and Concept Selection Matrix
- Architecture Rules to Maximize Customer Value and Minimize Cost
- Selecting Parameter Values to Maximize System Performance and Minimize Cost
- Simplification and the Impact of Architecture
- Simulate and Optimize the Concept Design
7. LEAN DESIGN ACTIONS DURING ASSEMBLY DESIGN
- The Power of Considering Assembly Design Alternatives
- Design for Assembly (DFA)
- DFA Principles & Guidelines
- The Key DFA Principle - Simplification
- DFA Exercise I
- Avoiding Non-Recurring Costs with Standardization
- Mistake-Proofing Assembly
- Assembly Process and DFA Principles
- Handling and Orientation
- Location and Insertion
- Joining and Fastening
- Adjustment & Finishing
- DFA Exercise II
- Design for Assembly with Electronics
- Design for Test - Developing an Economic Test Strategy
8. LEAN DESIGN ACTIONS DURING PART DESIGN/SELECTION
- Evaluating Material and Process Alternatives
- Trade-offs of Nonrecurring and Recurring Costs with Tooling and Near Net
Shape Parts
- Design for Manufacturability (DFM)
- Defining and Applying DFM Principles & Guidelines
- Reducing Costs with Early Supplier Involvement & Effective
Supplier Partnership
- Purchasing Actions to Reduce Cost
- Minimizing Supply Chain and Logistics Costs
- Designing in Quality and Robustness to Minimize Waste
9. LEAN DESIGN ACTIONS DURING PROCESS DESIGN
- Principles of Process Design for Low Cost
- Cost Reduction through Automation and Integration
- Re-engineering the Development and Production Processes
- Eliminating Non-Value-Added Activities
- Minimizing Cost Through Maximizing Process Capability
- Optimizing Tolerances for Low Cost
10. LEAN DESIGN PROCESS
- Process Steps to Achieve Lean Design
- Organizational Roles and Responsibilities for Lean Design
- Capturing Input and Feedback to Optimize Design
- Design Reviews and Other Verification Steps
- Essential Metrics to Track Target Cost Achievement
11. ACHIEVING LEAN DESIGN
- Challenging Your Assumptions
- Achieving Lean Design - Summary by Development Phase
- The 10 Steps to Lean Design
- Developing an Action Plan to Close the Gap
- Sources of Further Information
- Questions and Answers
12. LEAN DESIGN EXERCISE (OPTIONAL)
- Optional Exercises Analyzing Company Item(s) on Last Day
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