THE LEAN INNOVATION ROADMAP
Name: Joern Hoppmann
Advisor: Dr. Eric Rebentisch
A Systematic Approach to Introducing Lean in Product Development
Start Date: October 2008
Processes and Establishing a Learning Organization
1
MOTIVATION
2
GOAL OF RESEARCH
Expected Graduation: June 2009
3
LEAN PD COMPONENTS
Lean Principles
• Question of how to introduce Lean in Product Development
remains underinvestigated
4. Responsibility-based planning and control
5. Cross-project knowledge transfer
6. Simultaneous engineering
7. Supplier integration
8. Product variety management
9. Rapid prototyping, simulation and testing
Pull of the value
• Give recommendations on which sequence of steps is likely to
give best results when introducing the components of a Lean
Product Development System
3. Specialist career path
Striving for perfection
• Components that are characteristic of Lean Product
Development could be identified
2. Strong project manager
Creation of a continuous flow
• Investigate alternative orders of introducing the single parts of
a Lean PD system
1. Workload levelling
Specification of customer value
• Lean Product Development Systems have been studied by
several authors
• Based on
comprehensive
literature review
11 components
of a Lean PD
system were
identified and
described in
detail
Identification of the value stream
• Develop framework to systematically analyze the Lean PD
components and their interdependencies
Lean Product Development Components
• Rising awareness that use of Lean Principles in product
development offers large potential for increased efficiency
10. Process standardization
11. Set-based engineering
LEAN INNOVATION ROADMAP
• Data gathered through the
survey is currently being
analyzed to test the
hypotheses on the
introduction of Lean in
Product Development
• Based on the analysis,
recommendations for the
introduction process of Lean
PD will be derived
7
DATA GATHERING
6
United States
• The survey was distributed to
product development managers,
project leaders, and development
engineers, mainly in Germany and
the US
4
SURVEY DESIGN
5
• The hypotheses were translated into
an online-survey asking for
29%
– General information on the introduction
process
14%
Others
• More than 110 participants
• Companies responding are mainly
from automotive, electronics,
aerospace and industrial equipment
sectors
HOW CAN
LEAN PRINCIPLES
BE SUCCESSFULLY
IMPLEMENTED IN
PRODUCT DEVELOPMENT
SYSTEMS?
– The company‘s maturity level for each
component
– The perceived usefulness and difficulty
of implementation for each component
58%
Germany
– The order of introduction the company
has chosen
INTERDEPENDENCIES
… require this component
• Pairwise
interdependencies
of the components
were described
qualitatively and
quantitatively using
a cause-effect
matrix
How does this component…
8
Strong project manager
Specialist career path
Workload levelling
Responsibility-based
planning and control
Cross-project
knowledge transfer
Strong project manager
X
development of qualified
CEs, reliable concept
development and
planning due to help of
experienced engineers
reliable project planning
and progression due to
reduced over-burdening
of engineers, lower
waiting times, clear
priorization of activities
reliable project planning
and progression through
better adherence to
schedule and larger
motivation; reduced
planning efforts for CE
more reliable project
planning, cost and time
estimation
Specialist career path
CE as role model and
mentor; learning through
constant design reviews
X
Workload levelling
reduced variability in
processes through better
adherence to schedule,
clear concept, crossfunctional coordination
high availability of
functional specialists for
flexible planning; less
iterations through
standard skills, high
technical expertise
alignment of subgoals to technical expertise to set
customer value; frequent
goals, estimate time
control of adherence to
required and adhere to
goals and schedule
goals set
Responsibility-based
planning and control
Cross-project
knowledge transfer
Supplier integration
X
reduced variability
through better adherence
to schedule, larger
motivation
reliable planning of tasks
and estimation of time
required through clear
staggering and
priorization of projects
X
better understanding of
engineers for needs of
manufacturing
clear definition of
early integration and
requirements; early
synchronization of
identification of problems;
product development with
mentoring and teaching
suppliers
of suppliers
reduced variability in
demand for
manufacturing
representatives
higher incentive for
cooperating with
manufacturing due to
accountability and
ownership
reliable deadlines for
parts delivery
higher incentive for
integration of suppliers
due to accountability and
ownership
time for reviewing past
higher incentive for part
designs and structural
enforcement of reuse and high expertise in dealing
Common part
with particular part
best practices; time for reuse and modularization
modularization due to
CEs responsibility for cost functionality, geometry communication with other due to accountability and
architecture
ownership
and interfaces
designers to increase
and performance
reuse, define modules
autonomous development
seamless cooperation
of test plans; higher
availability of qualified
between designer and
incentive for early and
Rapid testing and
coordination of testing
testing personnel; testing testing and prototyping
intensive testing and
prototyping
and protyping
personnel when needed
competence among
prototyping due to
designers
accountability and
ownership
continuously improving
higher acceptance of
reduced variability in
standards; higher
higher adherence to
common processes due
processes through better
acceptance of common
schedule and linear
to more reliable project
Process standardization adherence to schedule;
processes due to
process steps through
runs and less waiting
reduced iterations due to
involvement of engineers
reduced iterations
times
clear concept
in updating
Set-based engineering
coordination of parallel
development and driver
for narrowing decisions
expertise for developing
alternative solutions,
defining interfaces,
weighing pros and cons,
choosing and merging
alternatives
Supplier integration
Common part
architecture
Rapid testing and
prototyping
Process standardization Set-based engineering
reduced variability
through avoidance of
unnessecary steps,
iterations and learning
more reliable planning of
more reliable planning of more reliable planning of better planning and easier more reliable planning of improved planning and
tasks due to reduced late
more reliable planning of
tasks due to large amount tasks due to fast sourcing control of tasks due to
tasks due to early and
control of tasks due to
tasks due to availability of
engineering changes,
of interaction with
and high quality of
clearly seperated
shorter problem-solving standard tools for design
past experience
high robustness of
manufacturing
delivered parts
modules
cycles
and communication
solutions
time for reviewing past
clear responsibility for
project findings before higher incentive for using
documentation of project higher ability for reflection
past knowledge due to
project start, time for
knowledge; enforcement
and documentation of
accountability and
reflection and
of checklists; knowledge
lessons learned
ownership
documentation of lessons
transfer through CE
learned,
enforcement of early
integration and
synchronization of
product development and
manufcaturing
Simultaneous
engineering
Simultaneous
engineering
more reliable project
more reliable proect
more reliable project
faster project planning
planning and progression
planning and progression planning and progression
more reliable project
more reliable project
and better control through
due to reduced late
due to early integration of due to early integration, planning and progression planning and progression
standard milestones,
engineering changes,
due to reduced design
due to early and shorter
manufacturing, parallel
careful outsourcing and
tools, documentation and
high robustness of
development of product high quality of delivered and testing requirements problem-solving cycles
communication
solution
and process
parts
increased and faster
learning through standard
respectful treatment of
better specialization and
increased and faster
increased and faster
process logic, reduced
suppliers as important
faster learning due to
learning through early
learning through
variability through
competence of product
clearly seperated
and shorter problemconsideration of wider set
standard tools,
solving cycles
development engineers
modules
of technical solutions
documentation and
communication
reduced variability
reduced variability
reduced variability
reduced variability
improved planning
through reduced design
through reduced late
reduced variability
through early integration through early integration,
through standard process
and testing requirements
engineering changes,
through early and shorter
of manufacturing/ parallel
careful outsourcing,
logic, predictable and
and parallel development
high robustness of
problem-solving cycles
development of product rigorous testing and fast
repeatable processes
of parts due to standard
solutions
and process
sourcing process
interfaces
expertise in
time for teaching,
enhancement of learning
enhancement of technical
manufacturing as
mentoring and reflection,
through higher
expertise through everimportant competence of
increased learning
involvement,
increasing knowledgeproduct development
through more reliable
accountability and
base
engineers
project runs
ownership
X
transfer of manufacturing
requirements and best
practice solutions
increased rate of
better documentation of
faster discovery of
better reuse of knowledge knowledge creation and
documentation and reuse
integration of supplier best practice of structures problems and higher rate
due to similarity of
documentation through
of knowledge on
requirements and ratings and designs due to lower of knowledge generation
subsequent projects and
consideration of wide
requirements of and
in documentations
part variability and clearly through early and shorter
tools employed
range of possible
design for manufacturing
defined interfaces
problem-solving cycles
solutions
X
documentation of supplier improved make-or-buy
performance, preferred decision making, precise
definition of requirements,
suppliers and their
mentoring of suppliers in
strengths and
manufacturing strategies
weaknesses
better synchronization of
early testing and
product and process
optimization of design for
development through
manufacturing and
standard procedures and
assembly
tools
earlier and stronger
integration of
manufacturing through
early consideration of
different alternatives
early integration of
manufacturing
requirements in supplier
contracts
reduced complexity of
parallel product and
process development
through standardized
modules and interfaces
X
reduced sourcing effort
through reuse; clear
seperation and
interchangeability of parts
and modules through
standard designs and
interfaces
faster formulation of
requirements and early
discovery of problems
with supplied parts
through early and fast
testing and prototyping
better integration of
suppliers through
standard procedure for
contracting, partnering
and sourcing
earlier and stronger
integration of suppliers
through involvement in
development of
alternatives and frequent
communication
X
higher robustness of
parts, modules and
platforms through early
and fast testing and
prototyping
standardized process for
increasing part reuse and
developing modules and
platforms
better understanding of
interdependence and
higher robustness of
parts, modules and
platforms
X
systematic and faster
testing and prototyping
through standard
procedures
improved testing and
prototyping through high
use
X
reduced variability
through reduced late
engineering changes,
high robustness of
solutions
high synchronization of
parallel processes
through standard
procedure, tools and
documentation
X
definition of standard
integration of
knowledge on feasibility
designs and interfaces for
manufacturing
of part reuse and
suppliers; integration of
modularity and interface requirements in modules
suppliers in module and
and reuse strategy
design from past projects
platform development
best practices in testing
and prototyping;
documentation of failure
modes
use of manufacturing
expertise in prototyping
and testing; early testing
for manufacturing
requirements and
assembly
faster testing through
reuse and standard
designs; independent
testing and prototyping of
parts and modules
through clearly seperated
modules
gathering of best practice
milestones and
procedures; best practice
standard tools
reduced variability of
processes due to early
integration of
manufacturing
fast sourcing of testing
equipment, prototype
parts and tooling;
rigorous testing
conducted by suppliers
reduced variability
reduced variability in
reduced variability of
through early integration,
processes through
processes through early
careful outsourcing,
increased reuse, standard and shorter problemrigorous testing and fast
designs and interfaces
solving cycles
sourcing process
consideration of
freezing and re-use of
development of
alternative manufacturing
time to follow several
autonomous development design sets from previous
processes; evaluation of alternative solutions and
alternatives in parallel
of alternatives and
projects; generalization of
narrowing in by suppliers;
alternatives for
and test them rigorously
accountability for results
solutions in trade-off
frequent communication
manufacturability and
before narrowing in
curves
robustness
clearly seperated
modules with standard
interfaces to be
developed in parallel
rigorous testing of design
sets; narrowing based on
profound information
base; gathering of
knowledge in trade-off
curves
HYPOTHESES
• Based on the
interdependencies of the
components
hypotheses on the
most efficient
order of
introduction were
formulated
5
Requires
other
components
(average 4
rating)
Set-based engineering
Product variety management
Responsibility-based
planning and control
or
de Mo
r o st e
f im ffi
Rapid prototyping
ple cien
and testing
me t
nt
Supplier integration
at
3
2
Specialist career path
Workload
leveling
ion
Strong
project
manager
Cross-project knowledge transfer
Process standardization
Simultaneous engineering
1
0
0
1
2
3
4
5
Is required for other components
(average rating)