Lean Product Development™
The following is a brief summary of Lean Product Development or Lean DFSS
(LDFSS) training and consulting available from SBTI.
For details on the following points download the Lean Product Development
White Paper below.
For Design for Six Sigma (DFSS) without the Lean elements, click
here.
If you have questions on how to deploy Lean Product Development, please click
on Lean Product Development Information for further details.
What is Lean Product Development™? (LDFSS)
The Lean Product Development for Six Sigma or Lean DFSS training methodology
can be considered a second generation of the widely adopted Design
For Six Sigma . The simplified notion is to design quality
and "leanness" into the product before it ever gets to the manufacturing
floor where Lean/Six Sigma Black Belts are working. In the ideal
world Lean Product Development™ Black Belts put Lean/Six Sigma Black
Belts to work on only manufacturing problems with
no design related problems being "solved" once production
begins. Lean Product Development™ Black Belts often work side-by-side
with their Lean/Six Sigma counterparts, using their expert knowledge
to solve process problems even before they happen. Included in
Lean Product Development are the Six Sigma Tools, DFSS tools, and Lean Manufacturing
tools and concepts that can be used by engineers working on new
designs.
How does Lean Product Development™ differ from Six Sigma or Lean-Sigma?
Lean Sigma and Six
Sigma target manufacturing and other business processes, whereas
the Lean Product Development™ methodology focuses within the product
development on a particular product. Lean / Sigma Black Belts
are taken from their existing functions to become a "fire-brigade",
tackling problem processes. Lean Product Development™ belts tend to remain
within their functions applying a stronger toolkit and design
problem solving methodology.
Benefits of undertaking Lean Product Development™ training come
from the following:
- Improved quality at product launch, because the product is
more tolerant to variation in both the supplied components and
the manufacturing process itself and has fewer raw material
components
- Faster development time
- Increased revenue due to the product being perceived of higher
value by the customer
- Reduced inventory costs due to fewer components and more re-use
of components across products i.e. fewer unique parts
- Reduced assembly times because the product has fewer components
and those that it does have are easier to manufacture
- Reduced product cost by better selection of material and manufacturing
process
Program Overview
- Business Case (understanding the market)
- Concept Development (understanding the customer)
- Lean Concepts
- Platform / System Architecture
- Introduction to Statistics
- Understanding manufacturing
- Product Design for manufacturability
- Optimizing the product
- Moving to capable manufacturing
There are 5 levels of attendance to the Lean Product Development™
training course:
- Executive - attends 1 day of training at the launch of initiative
to understand Lean Product Development™ concepts and philosophy, and
how to drive it in the business. Typical attendees are the executives
and senior business leaders.
- Champion - attends 3 days of training prior to first week
to learn what to expect of their Black / Green Belt(s) and how
best to support them. Typical attendees are the managers of
the initiative and Black Belt / Green Belt mentors.
- Black Belt - attends all 5 weeks of training and is required
to complete a project. Typical attendees are the project team
leaders.
- Green Belt - attends all of the first 3 weeks of training.
A Green Belt learns to an intermediate level of the Lean Product Development™
Design curriculum and is required to complete a project. Typical
attendees are the project team members.
- Week 1 - attends the whole of the first week of training to
understand the concepts central to the Lean Product Development™ philosophy
along with tools to strengthen the early stages of the NPI process.
Typical attendees are members of the project teams and anyone
in the company affected by the projects.
Expert Lean Product Development Consulting is available to SBTI customers
in the following areas:
- New Product Development (NPD) - If you need expert consulting
in any stage of development for a new product, be it concept,
design, optimization or launch, SBTI can help.
- NPD or Stage Gate Process Assessment - If your new product
development process or pipeline is not working as it should,
we can do an NPD assessment over several days with precise feedback
about what needs to change and why.
- Specific tools implementation and consulting - Be it Kano
Analysis, KJ, Pugh Concept or Design for Assembly, SBTI has
world class Lean Product Development consulting available to help your design
teams succeed.
Please click on Lean Product Development Information for further details.
Click
Here to download the .pdf white paper on Lean Product Development ™ (Lean
DFSS) ! 
245k
LDFSS Links
Software
DFSS with PS&J
Service & Process
Design (SSPD or Transactional DFSS)
Critical
Parameter Management Software for LDFSS (Cognition)
LDFSS Enterprise Project Management:
Instantis,
PowerSteering
Monte
Carlo Simulation(Crystal Ball),
Process
Simulation with IGrafx
LDFSS Tools & Methods Software:
Modular
Design Examples ,
QFD &
TRIZ with IdeaCore,
Reliability
Tools by Relex,
Tolerance
Modeling with VarTran
Lean Product Development Related Societies & Meeting Places:
Product Development
and Management Association,
The
Lean Construction Institute,
The Lean Enterprise
Institute,
ISixSigma,
IEEE,
ASME,
Society of Reliability
Engineers,
ISSSP
Six
Sigma Forum
Other Useful Links and Information:
Engineering
Statistics Handbook
The Patent
Cafe
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