Lean Aircraft Initiative
Plenary Workshop
Product Development Team
October 8, 1997
Presented By:
John Deyst
MIT
LEAN AIRCRAFT
INITIATIVE
Product Development
Cycle Time Reduction
Research and Framing
PD100897deyst-2 ©1997 Massachusetts Institute of Technology
LEAN AIRCRAFT
INITIATIVE
Cycle Time Structure
Technology Development
Cycle Time and
Risk Reduction
Requirements Analysis
Cycle Time
Idea Generation or
Need Identification
Product Development
Cycle Time
(Product and Process)
Decision to
Proceed
(Milestone 1 or
Project Launch)
Production
Cycle Time
Delivery of
First Production
Item
PD100897deyst-3 ©1997 Massachusetts Institute of Technology
DoD Product
Development Time
(Years)
LEAN AIRCRAFT
INITIATIVE
12
11
10
9
8
7
6
5
4
3
2
1
0
Aircraft
Helicopter
Electronic
Munitions
Missiles
Space
Ship
Other
Vehicle
System Type
All Major Defense Acquisitions Programs. Milestone 1 to First Operational Delivery
Data from RAND Selected Acquisition Report Database. Current as of Dec 1994.
PD100897deyst-4 ©1997 Massachusetts Institute of Technology
DoD Product
Development Time
LEAN AIRCRAFT
INITIATIVE
Years)
Actual
Projected
11
10
Projected
Actual
9
8
7
6
5
4
3
2
1
0
65-69
75-79
70-74
85-89
80-84
95-99
90-94
2000 and >
Year of First Operational Delivery
All Major Defense Acquisitions Programs. Milestone 1 to First Operational Delivery
Data from RAND Selected Acquisition Report Database. Current as of Dec 1994.
PD100897deyst-5 ©1997 Massachusetts Institute of Technology
LEAN AIRCRAFT
INITIATIVE
l
Commercial Cycle Time
Reduction Efforts
Reducing Product Development Cycle Time is the
Organizing Focus For Improvements in Commercial
Product Development Processes
l
‘Key to Making Changes in the System’
l
Obvious Commercial/Competitive Advantages
–
–
–
–
Dramatic Decreases in Cycle Time Achieved
Increased Quality
Decreased Development Costs
Dramatic Increases in Number of Products
Leading Metric of Product Development Effectiveness
PD100897deyst-6 ©1997 Massachusetts Institute of Technology
LEAN AIRCRAFT
INITIATIVE
Commercial Success at
Shortening Cycle Times
Industry
Old Time
Current
Goal
Automobile
7 years
2 years
<1.5 years
Commercial Aircraft
8-10 years
5 years
2 1/2 years
Commercial Spacecraft
8 years
1.5 years
1 year
Consumer Electronics
2 years
.5 years
PD100897deyst-7 ©1997 Massachusetts Institute of Technology
LEAN AIRCRAFT
INITIATIVE
LAI Product Development
Cycle Time Related Research
Programmatic
Aspects
– DoD Schedule
Process
Management and
Organizational Aspects
– IPT Effectiveness
– Make/Buy Decision
– Early Supplier
Integration in Design
– Design Structure
Matrix (Organizations)
– Risk Management
Engineering
Aspects
–
–
–
–
–
–
–
Database Commonality
Software Factory
Design Change Reduction
Key Characteristics
Design Structure Matrix (Product)
Architectural Innovation
Technology Insertion
PD100897deyst-8 ©1997 Massachusetts Institute of Technology
LEAN AIRCRAFT
INITIATIVE
l
Research Briefing Overview
Programmatic Aspects
“The Role of the Schedule Development Process”
Ross McNutt
Small group discussions
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Management and Organization Aspects
“Process Redesign and Management Using the Design
Structure Matrix Method”
Tyson Browning and David Grose (Boeing, Seattle)
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Engineering Aspects
“IPPD Process and First Time Capability”
Mario Vitale (Boeing, St. Louis) and Tim Cunningham
PD100897deyst-9 ©1997 Massachusetts Institute of Technology