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    All Rights ReservedPlease Do Not Copy Without Permission Brent Wahba LIPPD Ontario PDMA 3_30_10.ppt Page 1

    Lean, IntegratedProduct & Process Development

    Brent Wahba

    March 30, 2010

    [email protected]

    www.strategyscienceinc.com

    (585) 315-7051

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    If only we could

    develop better,easier to make

    products in halfthe timewith

    much less stress!!!

    Summary

    I can help you,

    but you willhave to LEARN

    to THINK & ACTDIFFERENTLY!

    Oh thank you

    Lean ProductDevelopment

    Consulting Man!Youve saved

    the day AGAIN!!!

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    Why Focus on Product Development?

    < 20% Of new

    products achieve

    their commercialobjectives

    Only 1 in 3,000

    ideas becomesa commercial

    success

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    1 month delay = 10% gross profit loss (average) (Sopheon)

    12 Month delay = 50% revenue loss in slow markets, 90% in fast markets (IBS)

    Introduction Growth Maturity Decline Time

    Units,R

    evenue,orProfit

    Total Units, Revenue, or Profit

    OptimalEntry

    Late

    Entry

    Why Focus on Product Development?Time to Market

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    Accounting Cost vs. Ability to Change Cost:

    0%

    10%

    20%30%

    40%

    50%

    60%

    70%

    80%

    Design Material Burden Labor

    Accounting Cost

    Ability to Change Cost

    Are We Working on the Wrong End?

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    What % of your Product Development

    time is typically Value-Added?

    Why Focus on Product Development?

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    Why Focus on Product Development?

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    What Would be the Impact of*:

    75% Fewerengineers to

    design a car?

    75% Less

    Production

    Scrap?

    Knowing which57 criteria

    customers buy

    based on?

    50% Less

    development

    lead time,

    30% lower total cost,

    with 25% fewer

    resources?

    > 75%

    Commercial

    successes?

    95 % Less

    prototype

    lead time?

    *Your results may vary

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    You cant solve todaysproblems at the same level

    of thinking you were at when

    you created them.

    Albert Einstein, Lean Thinker:

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    Definition: Value Streams

    2000

    Mix Form Glaze Fire Pack

    AAA CeramicPowder

    Mug-O-RamaSalesProduction

    Control

    P/T = 30 minL/T = 1200min%C&A = 95%

    P/T = 1 minL/T = 250 min%C&A = 99%

    P/T = 1 minL/T = 250 min%C&A = 65%

    P/T = 960 minL/T = 1080min%C&A = 85%

    P/T = 1 minL/T = 180 min%C&A = 65%

    P/T = 15 minL/T = 600 min%C&A = 95%

    P/T = 5 minL/T = 120 min%C&A = 98%

    Acme Mug Company1 Order / Day

    Phone2 P.O. / Week

    Fax

    2500 Per day

    27 Styles99.7% Defect-free

    1 Shipment/ Week

    1 Shipment/ Day

    1

    FIFO

    1

    1 500 500

    Phone

    ProductionAuthorization

    Job

    Packet

    2

    Coffee

    InIn

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    Companies are Really Quite Simple

    Product Development Strategy & Marketing

    R&D

    Design

    Supplier Selection

    Process Development Value Stream Design

    Tooling Implementation

    Test and Validation

    Continuous Improvement

    Make / Deliver Operations Sales & Marketing

    Manufacturing

    Supply Chain

    Distribution

    Service

    Continuous Improvement

    Product Development:Creating Production

    Value Streams

    Make / Deliver Operations:Operating Production

    Value StreamsCustomersCustomers

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    Simple, Standardized,Efficient, Robust,

    Development Process

    Product Development

    Customer NeedsProblems to solveWhat customers valueWhat they will pay forVoice of the Customer

    Competitive, profitable,capable, optimized:

    Product Definition,

    Service Definition,Process Definition &Production Value Streams

    Organizational NeedsStrategy, growth, profitStandardized workInternal requirementsRegulatory requirements

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    Lean is Ancientand Often Misunderstood

    Venetian ArsenalStandardization, Quality

    1320

    HonorBlancInterchangeable Parts

    1780

    Frederick TaylorScientific Management

    1911

    Meat Packing(Dis)assembly Line

    1867

    Ransom Olds1stAuto Assembly Line

    1901

    Ford, Highland Park PlantLinked & Paced Assembly

    1913

    Sakichi Toyoda, Taiiichi OhnoJIT, Defect Prevention

    1920 - 1990

    WWIITakt Time, TWI

    1940s

    Eliyahu GoldrattConstraints, Systems

    1984

    DemingPDCA, People, Quality

    1950s

    Scientific MethodEgypt, Socrates, Bacon, Galileo

    1600 BC1600 AD

    1991 Today

    http://www.google.com/product_url?q=http://www.powells.com/cgi-bin/biblio%3Finkey%3D1-9780060974176-18&fr=AIDChBOh9UxWeCExkKYoviAK1DxbfyhRKCH9zcbHyGEBlhTX3104dBKco3p8XDRly1VujpTtU-LBMS2jDBJR4He8UVkeUIzZVkEep1acnoeC7Eeza9b3eMkaKpe0tSwn2kLE2C1wys7RAAAAAAAAAAA&gl=us&hl=en&sa=imagehttp://en.wikipedia.org/wiki/File:EliGoldratt.jpghttp://en.wikipedia.org/wiki/File:W._Edwards_Deming.gifhttp://en.wikipedia.org/wiki/File:WomanFactory1940s.jpghttp://upload.wikimedia.org/wikipedia/commons/0/02/German_plane_bombing_Warsaw_1939.jpghttp://www.optiprise.com/FilesCustom/HTMLEditor/Images/Taichii_Ohno_large.jpghttp://en.wikipedia.org/wiki/File:Sakichi_Toyoda_new.pnghttp://en.wikipedia.org/wiki/File:DaviesPenofHogs.jpghttp://en.wikipedia.org/wiki/File:Olds2.jpghttp://en.wikipedia.org/wiki/File:Highland_Park_Ford_plant.jpghttp://en.wikipedia.org/wiki/File:Frederick_Winslow_Taylor_crop.jpghttp://upload.wikimedia.org/wikipedia/commons/2/2e/View_of_the_entrance_to_the_Arsenal_by_Canaletto,_1732.jpg
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    Delivering the most customer value

    while consuming the fewest resources

    Customer focus

    Respect & leverage our people

    Constant reuse, learning, problem solving

    Efficiency, effectiveness, prosperity

    Lean

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    ProjectManagement

    There really is no common definition

    What is Lean Product Development?

    LeanProductDevelopment(LPD)

    DesignForSix Sigma

    (DFSS)

    Systems

    Engineering(SE)

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    FakeLean

    WasteReduction

    Potential Lean Product Development Paths

    Which is best?What problem(s) are you solving?

    Do you want to change process and / or culture?

    LeanManufacturing

    / Design

    Factory

    DesignTools

    Queuing

    Theory /Flow

    ProjectManagement

    Modified6 Sigma /ProblemSolving

    AlWard

    ToyotaSystems

    Engineering/ SoftwareMethods

    OrganicGrowthModel

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    Key Lean Product Development Themes

    Development is not a deterministic process

    The output of development is reusable knowledge:

    How to satisfy customers

    How to perform work efficiently and effectively

    Validated, lean, capable production value streams

    Small batch sizes:

    Knowledge, experiments, design elements

    Cadence of small, fast learning cycles

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    Pull systems:

    Knowledge, customer-driven milestones

    Distributed project management

    Visual management

    Systems Engineering framework

    Explore alternatives

    Increase learning

    Manage high risk / high reward alternatives

    Key Lean Product Development Themes

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    Integrating events instead of quality checks

    Late concept selection with more knowledge

    Managing organizational capacity versus demand

    Project teams own the business

    Team leadership, team design, supplier integration

    Simple technology to fit team needs and processes

    Key Lean Product Development Themes

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    Organic Growth Model:Every Organizational Level Has Problems to Solve

    StrategiesBusiness Objectives

    Financial Performance

    Goals

    Budgets

    Operations

    Schedules

    Projects

    Assignments

    Rates

    Quality

    Standards

    Executives

    Managers

    Teams &

    Individuals

    A P

    C D

    A P

    C D

    A P

    C D

    A P

    C D

    A P

    C D

    A P

    C D

    A P

    C D

    A P

    C D

    A P

    C D

    Source (modified): Lean Transformations Group, LLC

    Grasp

    the

    Situation

    Adjust Plan

    Check Do

    P

    D

    C

    Learning /

    Problem SolvingCycle

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    Organic Growth Model of Lean Development

    Managing

    Work

    Customer

    Needs

    LeanProduct

    Development

    System

    Preparingfor Lean

    Production

    LPD System

    Design &

    Continuous

    Improvement

    Projects

    ReuseLearn firstExperimentsFailures

    Pull

    Small batchPrioritized OverburdenQuality @ sourceVisual

    Project management process

    Team-ownedSolution emerges

    from experimentsValue stream mappingA3 Problem solvingSimple toolsIntegration & reflection

    Product DesignProcess designValue stream designProduction validationProduction handoff

    End customersProductionBusiness

    P

    D

    C

    FastLearningCycles

    Grasp

    the situation,Create pull for

    change

    C t N d

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    Customer Needs:Untested Market Hypotheses?

    B t & P tt C B i J

    http://en.wikipedia.org/wiki/File:NewCokeCan1985.jpghttp://www.oobject.com/biggest-failure/betamax/83/http://images.google.com/imgres?imgurl=http://www.rickandheather.net/cars/worst20cars/pontiac_aztec.jpg&imgrefurl=http://www.bmwkraftur.is/spjall/viewtopic.php%3Ft%3D23263%26sid%3D9b2acf193da6f904529d805cf260d86e&h=300&w=400&sz=27&tbnid=WiEHxm53p-mXeM:&tbnh=93&tbnw=124&prev=/images%3Fq%3Dpontiac%2Baztec%26um%3D1&start=2&sa=X&oi=images&ct=image&cd=2
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    Brent & Pattys Car-Buying Journey:Learning and Decision Loops

    Pastbrand anddealershipexperience

    Pattyscar needsservice,getting

    old

    Newsstoriesof great

    rebates &deals

    Whatmodels?

    Check ads

    Online

    research,narrowconsideration

    set

    Checkads, decide

    potentialdealers

    Test drive,form / verify

    opinions

    Biasedanalysis,

    carselected

    Comparedealerprices,assesshonesty

    Considerimage impactwhere Patty

    works

    Investigatepricing anddiscounts

    Negotiatedeal,

    purchase

    Pick upcar, qualityitems not

    fixed

    Badservice /

    bad salesmanexperience

    Badservice

    experience,complaints

    Li ki t th C t J

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    Customer Journey

    (End customers, influencers, channels)

    Linking to the Customer Journey:Integrating Constant Learning

    BasicR&D

    SpecificR&D

    Product /Process

    Development

    ValueStream

    ImplementStart-Up Production

    Service/ Help

    StrategicPlanning

    Market

    Research

    ProductManagement

    Pricing /Placement /

    Promotion

    Selling FeedbackService/ Help

    Feedback

    Product Development Make / Deliver

    Inbound Marketing, Sales, Outbound Marketing, Service

    What Customers Need

    What WeCan Do

    C & C C

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    Market A Market B Market C Us Competitor X Competitor Y Competitor Z

    Attribute 1 1 4 5 2 1 1 4Attribute 2 10 20 10 7 15 20 7

    Attribute 3 1 1 2

    Attribute 4 Yes No Yes

    Attribute 5 Blue Blue, red Red

    Attribute 6 5 ppm 3 ppm 12 ppm

    Attribute 7

    Attribute 8

    Attribute 9 Local rep. Regional rep. Local rep.

    Attribute 10

    Attribute 11

    Attribute 12 China China, Korea All-Asia

    Attribute 13

    Attribute 14

    etc.

    Attribute 15 Foam Cardboard Wood

    etc.

    Attribute 16

    CriticalAttribu

    tes

    Performance

    QR

    D

    Service

    Deliv

    ery

    Call out

    requirement

    used for

    comparison

    Use Visual

    management

    to highlightgaps

    Market,

    Customer,

    Program

    Capturing & Communicating Customer Needs:Value Proposition Example

    What are the

    significant

    attributes for

    customer buydecisions?

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    And Some Needs are Better Left Un-Served

    News in Brief

    Fork Manufacturer Introduces Fifth Tine ToAccommodate Growing American Mouthfuls

    February 17, 2010 | ISSUE 4607

    EVANSVILLE, INIn an effort to keep pace with the rapid growth of American mouthfuls, flatwaremanufacturer KitchenMaster announced yesterday the addition of a fifth tine to its line of dinnerforks. "These days, a traditional four-tined fork is just not enough to handle the quantities of foodpeople shove down their throats," said company spokesman Ken Krimstein, holding up a forksupporting six separate tortellini, two turkey sausages, and some mashed potatoes. "To stayrelevant to our customer base and bring back some of those who have given up on using utensils

    entirely, this was an adjustment we just had to make." Krimstein added that the augmented forks

    would soon be followed by 25 percent deeper spoons and3-gallon gravy boats.

    Source: The Onion

    L P d t D l t S t D i

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    Lean Product Development System Design:Value Stream Mapping

    UpdateConcept

    ReviewData

    StudyMfg.Cost

    Mfg.Concept

    StudyMfg.

    Manufacturing

    ReviewData

    QuoteSuppliers

    SelectSuppliers

    StudySupplyBase

    BuyerPurchasing /Supply Chain

    UpdateConcept

    ReviewData

    StudyInvestment

    Tooling

    UpdateConcept

    ReviewData

    StudyProcess

    ProcessConcept

    StudyProcess

    ProcessManufacturingEngineering

    TestConcept

    Test

    BuildConcept

    Prototype

    UpdateConcept

    ReviewData

    DesignConcept

    StudyDesign

    Design

    ProductEngineering

    StudyBusiness

    Case

    PrepareQuote

    Finance

    TriggerProject

    ProspectSales

    SelectMarkets

    Marketing

    CreateStrategic

    PlanPlanning

    Commercial

    Review /Approve

    Design

    Review /Approve

    Quote

    ReviewProposal

    Customer

    Higher level /

    less detail than

    manufacturing

    mapping

    Current state:

    Customer value,Quality & rework,

    Delays & interruptions,

    Knowledge growth,

    Biases / assumptions,

    Prioritize problems

    Future state:

    All customer needs,

    Quality at handoffs,Existing solutions,

    Solution experiments

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    If HP knew what HP knew,

    we would be

    3 times as profitable.Lou Platt,

    Former CEO,Hewlett-Packard

    Fast Learning Cycles

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    Why Learning First Works

    Common causes of failure / rework:

    Resources not available

    Requirements change (or become known)

    Validation failure or does not meet updated customer requirements

    Product and process are incompatible / does not meet internal requirements

    Project does not meet commercial requirements

    No low risk back-up plan

    Concept #1

    Concept #2

    Concept #3

    Concept #4

    DesignSolutionSelected

    DesignDevelopment

    Production

    PerceivedCustomer

    Requirements

    ProcessDevelopment

    ProcessSolutionSelected

    Typical Point-Based Product Development

    Rework Rework Rework Rework Rework

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    Sub-System

    Mapping theDesign / Process /Customer Space

    DefineNarrowing

    Criteria

    Concept NarrowingAnd Integrating

    FinalDefinition &Validation

    Concept #1

    Concept #2

    Concept #3

    Concept #4

    Concept #1

    Concept #2

    Concept #3

    Concept #4

    Sub-SystemA

    Sub-SystemB

    Customer

    Technology

    Manufacturing

    Cost

    Quality

    Suppliers

    #1

    #2

    #3

    #4

    #1

    #2

    #3

    # 2 & # 3

    # 4

    # 1

    # 2

    FinalConcept

    Final

    Concept

    Choose optimalintersection ofsub-systems

    Customer

    Technology

    Manufacturing

    Cost

    Quality

    Suppliers

    Learning First + Controlled Narrowing

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    Concept Narrowing While:Increasing Knowledge

    Increasing Detail & FunctionalityIncreasing Optimization & RobustnessIncreasing Quality / Reducing Risk

    Workload Leveled

    Learning First + Controlled Narrowing

    LearningCycle Final

    Design,Process, &

    Value Streamin Production

    OutlineSystem

    Structure

    Mapping theDesign / Process /Customer Space

    Learning, Narrowing,& Integrating

    DetailedDesign,Process,

    Value Stream,Validation

    Fast,Standardized,

    No Surprises

    No ReworkOnly Production

    ContinuousImprovement

    Linked Learning Cycles

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    Linked Learning CyclesLeads to More Useful Knowledge

    CustomerNeeds

    Strategy

    Internal& Partner

    Capabilities

    Product

    Development

    Process

    A P

    C D

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    Swiss Federal Institute of Technology study of

    the causes of catastrophic structural failure:1) Insufficient knowledge ........................................... 36%

    2) Underestimation of influence ................................. 16%

    3) Ignorance, carelessness, negligence .................... 14%

    4) Forgetfulness, error ............................................... 13%

    5) Relying upon others without sufficient control ........ 9%

    6) Objectively unknown situation ................................ 7%

    7) Imprecise definition of responsibilities .................... 1%

    8) Choice of bad quality .............................................. 1%

    9) Other ....................................................................... 3%

    Learning Through Failures

    Knowledg

    e

    Management

    Issues

    ProductDevelopm

    ent

    P

    rocessIssues

    Managing Work:

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    Managing Work:Common Project Management Evolution

    1. Under-defined, wasteful, inadequate development process

    2. Standardized statements of work by organizational function3. Gates / quality checks

    4. Training

    5. Major quality reviews

    6. Automation

    7. Training

    8. Kaizen workshop

    9. Training

    10. New methodology

    11. etc

    Every change implies a different process. Why?

    What problem is each step trying to solve?

    What is the real root cause?

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    Projects are the deployment of a strategy

    Projects are all about creating and applying useful knowledge

    What do we need to do?

    What do we need to know to do it?

    By when, by whom, and how?

    Who is the customer of the project management process itself?

    Lean Project Management

    Continuous Improvement

    Product Development Value Stream Implementation

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    No box-checking allowed:

    1. What is the product and / or service?

    2. What are the delivery and service value streams?

    3. Does it meet the customers needs?

    4. Will it have acceptable quality at every customer touch point?5. Does it fit our strategy?

    6. Does it represent an acceptable investment of $s and resources?

    7. What has changed and what are our countermeasures?

    8. What went wrong and how do we prevent it from happening again?

    9. What have we learned and how can we reuse it?

    Question-Based Lean Project Management

    Integrating Learning Loops

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    Integrating Learning LoopsInto Project Management

    Customers &Deliverables

    TargetCustomers

    Quote /Specs

    Prototype1

    Prototype2

    Quote /Specs

    Quote /Specs

    ApprovalParts

    ProductionPartsStrategy

    What is theProduct?

    What is theProcess?

    What is theValue Stream?

    Do we MeetCustomersRequirements?

    Do we MeetInternalRequirements?

    Learning /ProblemSolving

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    X

    Managing Work:

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    Managing Work:Organizational Capacity vs. Requirements

    2008 2008 1/2 2009 2009 1/2 2010 2010 1/2

    Product

    3

    Product

    4

    Product

    1

    2011

    Value

    Stream

    1

    2011 1/2 2012

    Product

    2

    Value

    Stream

    2

    MarketA

    Mark

    etB

    MarketC Danger!

    All Good

    All Good

    All Good

    All Good

    Development teams are most efficient / effective at 70 - 80% capacity

    Prioritize and balance workload; manage capacity versus requirements

    Align organization behind the strategy & priorities

    Warning

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    Customer

    MilestonesRequirements

    Defined Quote Prototype ValidationProduction

    DesignStart of

    ProductionContinuous

    Improvement

    Project 1

    Plan:

    Actual:

    9/1/05

    9/1/05

    10/1/05

    10/1/05

    11/1/05

    11/1/05

    1/15/06

    1/15/06

    2/1/06

    2/1/06

    4/1/06

    4/1/06

    4/15/06

    4/15/06

    Project 2

    Plan:

    Actual:

    9/1/05

    9/1/05

    10/1/05

    11/1/05

    11/1/05

    12/1/05

    1/15/06

    2/15/06

    3/1/06

    3/15/06

    4/1/06

    4/15/06

    4/15/06

    5/1/06

    Project 3

    Plan:

    Actual:

    9/1/05

    9/1/05

    10/1/05

    11/1/05

    11/1/05

    12/1/05

    1/15/06

    1/15/06

    3/1/06

    2/1/06

    4/1/06

    4/1/06

    4/15/06

    4/15/06

    ! ! ! !

    Which project is fine? Needs watching? Is in trouble and needs intervention?

    Draw attention to where help is needed and do not spend too much time onitems that are on-track

    Visual Project Management Example

    P j K b E l

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    1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

    Design

    Test

    Process

    Purchasing

    Finance

    Manufacturing

    Week

    Project Kanban Example

    TeamDeliverable

    CustomerDeliverable

    Deliverableis Late!

    Current

    Preparing for Lean Production:

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    Its not a product

    if you cant make

    and deliver it.

    Preparing for Lean Production:Creating & Validating Production Value Streams

    2008 BBB C l i t

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    2008 BBB Complaints

    Category Rank # of Complaints

    Cell phones & carriers 1 35,631

    Auto dealersnew cars 2 26,723

    Auto dealersused cars 7 12,958

    Auto repair & service 12 11,157

    Auto parts & supplies 39 4,303

    Auto warranty companies 44 4,073

    Auto rental & leasing 61 3,075

    Auto manufacturers 108 1,749

    Business consultants 127 1,407

    Puppets & marionettes 590 2

    Zinc oxide 2,408 0

    Majority of autocomplaints are

    value stream /service related

    KFC V l St D b l

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    KFC Value Stream Debacle

    We are so sorry, but due to the overwhelming response to our FREE KentuckyGrilled Chicken meal coupon, we can no longer redeem the free coupon at

    this time. But we will honor our commitment to giving you a free KentuckyGrilled Chicken meal.

    Please visit a participating KFC restaurant for a rain check form. Complete theform, attach your original coupon , and give it to the KFC restaurant manageror postmark per the forms instructions, by May 19, 2009, and well send you a

    rain check for your free Kentucky Grilled Chicken meal at a later date, plus afree Pepsi with our compliments. Your participating KFC restaurant will provideyou with the form you need.

    Please note that the redemption periods of the rain checks will vary. All otherterms and conditions of the original free Kentucky Grilled Chicken coupon will

    apply.

    Thank you for your understanding,

    Roger EatonKFC President

    C ti th M C f V l St

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    Creating the McCaf Value Stream

    Biggest launch since Egg McMuffin

    11,000 Restaurants (just U.S.)

    $100 MM in launch costs

    Cappuccinos, lattes, mochas, iced

    lattes and iced mochas, as well ashot and iced Premium Roast brewed

    coffees and hot chocolate. AllMcCaf Coffees start with fully-ripened Arabica coffee beans fromCentral and South America andIndonesia. From there, each drink ismade to order with quality

    ingredients like flavored syrups,including caramel, hazelnut, vanillaand sugar-free vanilla, richchocolate, frothy steamed milk andwhipped cream.

    Process & Value Stream Design

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    What impact does paintcolor have on cycle time?

    If we localize solenoid production

    in Brazil to reduce duties, can weuse the same solder?

    How is labor linearity impactedby the features we offer?

    Process & Value Stream DesignOften Interact with Product Design

    Process & Value Stream Design Should

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    Process & Value Stream Design Shouldbe Treated Like a System Design Problem

    2000

    Mix Form Glaze Fire Pack

    AAA CeramicPowder

    Mug-O-RamaSalesProduction

    Control

    P/T = 30 minL/T = 1200min%C&A = 95%

    P/T = 1 minL/T = 250 min%C&A = 99%

    P/T = 1 minL/T = 250 min%C&A = 65%

    P/T = 960 minL/T = 1080min%C&A = 85%

    P/T = 1 minL/T = 180 min%C&A = 65%

    P/T = 15 minL/T = 600 min%C&A = 95%

    P/T = 5 minL/T = 120 min%C&A = 98%

    1 Order / DayPhone

    2 P.O. / WeekFax

    2500 Per day27 Styles

    99.7% Defect-free

    1 Shipment/ Week

    1 Shipment

    / Day

    1FIFO

    1

    1 500 500

    Phone

    ProductionAuthorization

    JobPacket

    2Coffee

    InIn

    I t ti P & V l St D l t

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    Sub-System

    Mapping theDesign / Process /Customer Space

    DefineNarrowing

    Criteria

    Concept NarrowingAnd Integrating

    FinalDefinition &Validation

    Concept #1

    Concept #2

    Concept #3

    Concept #4

    Concept #1

    Concept #2

    Concept #3

    Concept #4

    Sub-SystemA

    Sub-SystemB

    Customer

    Technology

    Manufacturing

    Cost

    QualitySuppliers

    #1

    #2

    #3

    #4

    #1

    #2

    #3

    # 2 & # 3

    # 4

    # 1

    # 2

    FinalConcept

    Final

    Concept

    Choose optimalintersection ofsub-systems

    Customer

    Technology

    Manufacturing

    Cost

    Quality

    Suppliers

    Integrating Process & Value Stream Development

    Lean Product Development Example #1:

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    Lean Product Development Example #1:Toyota Product Development System

    1. Establish customer-driven value

    2. Front-load design process to explore alternatives

    3. Create level development flow

    4. Standardization to reduce project outcome variation

    5. Chief Engineer / Super Program Manager

    6. Balance functional expertise and cross-functional integration

    7. Create Towering Technical Competence

    8. Integrate suppliers into development process

    9. Built-in learning and continuous improvement

    10. Culture to support excellence and relentless improvement

    11. Adapt technology to fit people and process

    12. Align organization through simple, visual communication

    13. Tools for standardization and organizational learning

    Sources: The Toyota Way, The Toyota Product Development System, Lean Product and Process Development

    Lean Product Development Example #2:

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    Lean Product Development Example #2:Apple (?!!!)

    Controlled concept narrowing

    Fast cycles of learning / cadence of review Simultaneously exploring concepts and developing detailed

    implementation plans

    Concept is selected at the very end of the process

    Strategically focused organization

    Small, focused teams

    Supplier partners

    Market experimentation Narrow set of must have features / functions (value focus)

    Look and feel

    Pulling It All Together

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    Pulling It All Together

    Organically grow your own lean product development process:

    1. Do not copy Toyota or Apple! (but you can learn from them)2. What are your business needs? What problems do you need to solve?

    3. Current state: What works well? Problems & gaps?

    What are the real root causes? (not the symptoms)

    4. Future state vision: What / Who / How / When? Quality measurements?5. Implementation plan:

    When does the business need it completed?

    Does the organization have enough capacity?

    What are reasonable chunks to work on?

    What simple experiments will test your future state vision (hypotheses)?

    PlanDoCheckAdjust

    Honest reflection and improvement

    About Us

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    Strategy Science Inc. is a global product development, strategic planning, and sales &marketing consulting / training firm.

    We are focused on improving your process efficiency and effectiveness.

    Our objective is to teach you to become self-sufficient in learning, problem solving, anddriving continuous improvement. We will have achieved that goal when you can maintainyour own desired pace of improvement without us.

    We support you with organizational problem analysis, training combined with pilotprojects, and management coaching.

    Our work is custom tailored to your specific needs. We work closely with you to jointlyuncover gaps, create solutions, and implement rather than forcing our own set of favoritesolutions.

    We are a network of 10 experienced practitioners with extensive knowledge of how tobest implement what we teach.

    To learn more, please visit our website: www.strategyscienceinc.com or contact ourpresident, Brent Wahba, at (585) 315-7051 / [email protected]

    About Us

    http://www.strategyscienceinc.com/mailto:[email protected]:[email protected]://www.strategyscienceinc.com/
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    Thank You!!!