1. 1 Itzhak Ben-Levy LEAN Expert © LEAN Product Development (LPD) October 2012 Itzhak Ben-Levy - LEAN Expert 972-523579166 itzhak@benlevy.co.il www.benlevy.co.il

2. 2 Itzhak Ben-Levy LEAN Expert © "A systematic approach to identifying and eliminating Waste through continuous improvement " Lean Definition Lean is about our people – Train them, Empower them, Trust them, Motivate them, Engage them

3. 3 Itzhak Ben-Levy LEAN Expert © The Development Problems Long development cycle times Many redevelopment cycles High development costs Long production cycle times High production costs

4. 4 Itzhak Ben-Levy LEAN Expert © In The Box Out Of The Box What is the best way to understand what is going on ? Each one Separately see Part of the picture Everyone see together all the picture

5. 5 Itzhak Ben-Levy LEAN Expert © LEAN LEAN Manufacturing LEAN Product Development

6. 6 Itzhak Ben-Levy LEAN Expert © The main Principles Of Lean Product Development Establish customer-defined value Front-load the product development process Create a level product development information flow Organize to balance functional expertise and cross-functional integration Align your project through simple visual communication

7. 7 Itzhak Ben-Levy LEAN Expert © IPT PRINCIPLES Focus on a product Multidisciplinary team Co - location Team working

8. 8 Itzhak Ben-Levy LEAN Expert © IPT Integrated Product Team Engineerin g Stress Manufacturi ng Quality & System Safety Productio n IPT Leader SUPLIER Analysis CUSTOM ER Ron Bill Ronny Dan Sam Gil Neb Roth Bob

9. 9 Itzhak Ben-Levy LEAN Expert © LPD principle TOOLS LEAN FACILITATOR IPT PROJECT MANAGER LPD workshop LPD TOOL TO DO LIST Just Do It!

10. 10 Itzhak Ben-Levy LEAN Expert © Workshop TO DO LIST N° PROBLEM / ISSUE / OPPORTUNITYCOUNTERMEASURE / EXPECTED RESULTSSTARTCOMPLETERESPONSIBLESTATUS Project :Team Leader: DATE :

11. 11 Itzhak Ben-Levy LEAN Expert © Development plan workshop

12. 12 Itzhak Ben-Levy LEAN Expert © LPD Gates 1.SRR – SYSTEM REQUIREMENT REVIEW 2.DRR – DESIGN READINESS REVIEW 3.PDR – PELIMINARY DESIGN REVIEW. 4.CDR – CRITICAL DESIGN REVIEW. 5.TRR –TESTS READINESS REVIEW 6.TRDR – TEST RESULT DESIGN REVIEW 7.PRR – PRODUCTION READINESS REVIEW 8.FAI – FIRST ARTICLE INSPECTION

13. 13 Itzhak Ben-Levy LEAN Expert © The process Time – days / weeks / month ACTIVITIES LEGENT FUNCTIONAL DEPARTMENTS Main milestones

14. 14 Itzhak Ben-Levy LEAN Expert © Templates for capturing new data and information A focus on value creating activities New insights into the development process Real time reallocation and synchronization activities Discover Unknown - unknown Team identity and emotional commitment Common language among team members To do list identifying new corrective actions Outcome of LPD workshop Reducing development lead time and cost by:

15. 15 Itzhak Ben-Levy LEAN Expert ©

16. 16 Itzhak Ben-Levy LEAN Expert © 16 Value to the customer Solving customer Problems Exploiting Opportunities The product should Look good The Customer should Feel good

17. 17 Itzhak Ben-Levy LEAN Expert © 17 QFD shorten cycle time by: 1.Understanding value to the customer 2.Exploiting customer needs 3.Deriving and consolidation of the requirements from customer needs 4.Prioritizing requirements 5.Allocating requirements to the project team

18. 18 Itzhak Ben-Levy LEAN Expert © ONCE PRICE = PROFIT + COST What the customer pays "by product" of the design Determined by the corporate

19. 19 Itzhak Ben-Levy LEAN Expert © NOW COST = PROFIT - PRICE Determined by the corporate Determined by the competitors Determined to the project manager DTC - Design To Cost

20. 20 Itzhak Ben-Levy LEAN Expert © How the engineer now how to design? casting welding machining forging Sub contracting riveting The cost target determined it

21. 21 Itzhak Ben-Levy LEAN Expert © Not important Important Low High Requirements (QFD) Accept all Consider to delete delete challenge Implementation Cost (DTC) Reduce requirements And cost

22. 22 Itzhak Ben-Levy LEAN Expert © Cost Reduction workshop Project manager DFMA Tools Facilitator Challenge the design Multidisciplinary Team Requirements Architecture Technology Assembly Reuse COTS Standards Symmetry Tolerances No. of Parts Tests Commonality

23. 23 Itzhak Ben-Levy LEAN Expert © How to integrate the production and procurement into development process The project manager should require a real cost status in each gate Multidisciplinary Team

24. 24 Itzhak Ben-Levy LEAN Expert © Engineering Requirements Reduction Cost Reduction Supplier Suppliers costs reduction Costs drivers Requirements Priorities

25. 25 Itzhak Ben-Levy LEAN Expert © "What's it in for me?" Project Manager Shorten Time to Market Reducing manufacturing costs Reduction of problem solving meetings of the project. The project team itself solves the most problems and takes its responsibilities without management involvement. Information provided to management is more reliable and realistic with maximum transparency Introduction of a culture that allows to deal with complex issues and find solutions agreed upon in a very short time.