Lean Product Design

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Lean Product Design

• LPD - product or product development process that
  delivers value with minimal waste. Value means
  benefits for the customer, your company, your
  supply chain, and any other stakeholders affected
  by the creation and use of the product.
• Product - the sum of all elements a product
  requires over the span of its lifecycle
  includes not only physical parts but also the
  tasks required to design, manufacture, sell,
  service and dispose of it.

Bart Huthwaite, The Lean Design Solution,
Institute for Lean Design (2004)
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Lean Product Design

• Lifecycle - products existence from lust to
  dust. (Some of the most disastrous mistakes are
  made in the lust phase some of the most
  expensive costs can be in the disposal phase.)
• Design tasks done and actions taken to develop
  the physical product, and the organizational
  processes used to support the physical design
  effort.
• Over 60 of all new product development efforts
  are terminated before they ever reach the
  marketplace. Of the 40 that do make it, more
  than half fail to become profitable or are
  removed from the market.

Bart Huthwaite, The Lean Design Solution,
Institute for Lean Design (2004)
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Lean

• Originally applied to manufacturing (Toyota
  Production Method) meant less of everything,
  from inventory to labor to machines. Strip away
  all wasted effort.
• Wide-spread use today
• No longer enough factory floor solutions can
  only do so much requires preventive measures
• Now, lean from the start of product development
• Design is the primary ingredient for a
  products true success hence, LPD.

Bart Huthwaite, The Lean Design Solution,
Institute for Lean Design (2004)
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Toyota as a lean pioneer

• Promoted and delivered lean manufacturing
• Moved to lean product design with astounding
  results, and without reliance on tools and
  techniques in vogue in the Western world
• No formal phase-gate product development
  process, no formal six-sigma process, little
  reliance on QFD, VSM, DFM, or FMEA.
• Toyota product development process has been
  difficult to copy

Bart Huthwaite, The Lean Design Solution,
Institute for Lean Design (2004)
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Toyotas Six-Point Product Design Approach

• Deep understanding of the values customers seek
• Close supplier integration in the design process
• Strong technical and entrepreneurial project
  leadership
• Retention of knowledge for easy retrieval and
  re-use
• Strong knowledge sharing and convergence between
  stakeholders
• High workforce skills and sense of responsibility

Michael Kennedy, Product Development for the Lean
Enterprise Why Toyotas System is Four Times
More Productive and How You Can Implement It
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Lean Design Equation

• Optimize Product Values, Prevent Wasteful
  Processes
• Product Values all product characteristics that
  customers desire (affordability, usability,
  reliability, maintainability) and which benefit
  the company (manufacturability, marketability,
  growability)
• Wasteful Processes those activities along a
  products total life cycle that do not create
  value (training, tracking, installing,
  documenting, servicing, packaging, monitoring,
  disposing)

Bart Huthwaite, The Lean Design Solution,
Institute for Lean Design (2004)
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The Five Laws of Lean Design

• Law of Strategic Value
• Optimize product values (customer and company)
• Law of Waste Prevention
• Minimize wasteful processes
• Law of Marketplace Pull
• Attempt to predict what values customers truly
  need, now and in the future see emerging trends
  early, grow by discovering unmet needs to create
  disruptive strategy.

Bart Huthwaite, The Lean Design Solution,
Institute for Lean Design (2004)
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The Five Laws of Lean Design

• Law of Innovation Flow
• Need systematic way for all stakeholders to
  contribute innovative ideas seek many solutions
  simultaneously.
• Law of Fast Feedback
• You can only improve what you can measure.
  Common metrics are schedule, budget, technical
  performance. But, need to measure what is
  important to customer measure for direction
  first, precision later. Enable those who will be
  measured to create the measurement system.

Bart Huthwaite, The Lean Design Solution,
Institute for Lean Design (2004)