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Superfactory ®  Lean Enterprise Series Lean & Six Sigma Design
Outline ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Lean Design & Six Sigma Phase 2 Concept Phase 1 Pre-concept Phase 3 Product Definition Phase 4 Detailed Design Phase 5 Integration & Test Validation Phase 6 Production & Operation CUSTOMER C T Q ’ S B U S I N E S S C T Q ’ S T E C H N I C A L C T Q ’ S T E C H N I C A L R E Q U I R E M E N T S L I S T Manufacturing Process Control Design for Six Sigma Product Development Process Lean Design Supplier Rationalization Quality Improvement Cycle Time and Cost Improvement
Key Lean Design Concepts ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Toyota System ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Product Development
Waste in Product Development Waste Category Example Implication Defective Products Excessive Inventories Excessive Motion Excessive Processing Transportation Waiting Over Production ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Cycle Time Issues Excessive  Product Development Cycle Time  11 Months on  Average Why ? Rework Loops From Detailed Design Starting Before Product Reqs. Are Defined Detailed Design  Takes Too Long Requirements Capture & Lockdown Takes Too Long Why ? Why ? No Process for Requirements Capture Lack Reqs. Lockdown  Discipline Lack Similar  to Product  Capabilities Capable  Resources  not Available Redesign  Rather than  Reuse Capable  Products Supplier  Selection Time  Delay (6 weeks) Long Lead Time  Parts Procurement Delay (12weeks) Why ? Why ?
[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Design for Six Sigma Goals

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Lean Design Sample

  • 1. Superfactory ® Lean Enterprise Series Lean & Six Sigma Design
  • 2.
  • 3. Lean Design & Six Sigma Phase 2 Concept Phase 1 Pre-concept Phase 3 Product Definition Phase 4 Detailed Design Phase 5 Integration & Test Validation Phase 6 Production & Operation CUSTOMER C T Q ’ S B U S I N E S S C T Q ’ S T E C H N I C A L C T Q ’ S T E C H N I C A L R E Q U I R E M E N T S L I S T Manufacturing Process Control Design for Six Sigma Product Development Process Lean Design Supplier Rationalization Quality Improvement Cycle Time and Cost Improvement
  • 4.
  • 5.
  • 6.
  • 7. Cycle Time Issues Excessive Product Development Cycle Time 11 Months on Average Why ? Rework Loops From Detailed Design Starting Before Product Reqs. Are Defined Detailed Design Takes Too Long Requirements Capture & Lockdown Takes Too Long Why ? Why ? No Process for Requirements Capture Lack Reqs. Lockdown Discipline Lack Similar to Product Capabilities Capable Resources not Available Redesign Rather than Reuse Capable Products Supplier Selection Time Delay (6 weeks) Long Lead Time Parts Procurement Delay (12weeks) Why ? Why ?
  • 8.