Lean Design Guidebook - Everything Your Product Development Team Needs to Slash Manufacturing Costs

328 Pages·2004·43.326 MB·English

by  Mascitelli, Robert

The
Lean Design
Guidebook
Everything Your
Product Development Team
Needs to Slash Manufacturing Costs

Ronald Mascitelli
?=-
TECHNOLOGY PERSPECTIVES
Northridge, CA
@ Copyright 2004 by Technology Perspectives
All rights reserved
Editorial and Sales Offices: Technology Perspectives
18755 Accra Street, Northridge, CA 91326
[phone]
Publisher’s Cataloging-in-Publication
(Provided by Quality Books, Inc.)
Mascitelli, Ronald.
The lean design guidebook : everything your product
development team needs to slash manufacturing cost / by
Ronald Mascitelli. -- 1st ed.
p. cm.
Includes bibliographical references and index.
LCCN 2004101401
ISBN 0-9662697-2-1
1. Design, Industrial. 2. Manufacturing processes --
Cost control. 3. Production planning. I. Title
TS171.4.M373 2004 658.5’752
QB104-200121
10 9 8 7 6 5 4 3 2 1
First Edition
This book is printed on acid-free recycled paper meeting
the requirements of the American National Standard for
Permanence in Paper for Printed Library Materials.
Manufactured in the United States of America
In trod uction
- About This Guidebook
There’s waste in your product designs, and it’s costing you a
...
fortune! Oh, it may not look like waste to you at least not yet.
But soon you will begin to see the profits that are being squandered
and the opportunities being missed. More important, you will learn
how to solve cost problems at every stage of product development.
You are about to begin a guided tour of product cost-reduction meth-
ods, beginning at the earliest stages of project selection, and ending
with the launch of a successful and highly profitable new product.
Along the way, I will introduce you to eighteen lean design tools that
are practical, efficient, and immediately deployable. Each tool
addresses a specific opportunity for cost reduction during product
design: As a group they represent an integrated approach to achiev-
ing the highest possible product value at the lowest achievable
manufacturing cost.
Before we go further, let’s establish the intended audience
for this book. This is a guidebook for practitioners, by a practitio-
ner. All of the methods you will learn can be implemented at the
level of an individual designer, a product development team, or even
throughout an entire organization. In other words, these tools are
meant to be used. If you are a member or leader of a product design
team, welcome to the tour. If you manage an engineering, market-
ing, or manufacturing organization, please join the group. Improve-
ment champions, manufacturing engineers, Six-Sigma blackbelts,
quality specialists, procurement folks; you’re definitely in the right
place. If your firm is committed to lean manufacturing and looking
to expand its success, you deserve a front-row seat; the tools in this
guidebook are specifically designed to dramatically enhance your
efforts toward a lean enterprise. Other interested readers are welcome as well ...p rovided
that you are comfortable with the pragmatic (and decidedly informal) tone of this material.
Just a few administrative details and we’ll be on our way to the first stop on our
journey. I’ve described this work as a guidebook, and that is the analogy you should keep
in mind as you proceed. It is my intention that this book become dog-eared and worn
through constant use. Graphics are used extensively to illustrate key concepts. Tem-
plates, forms, and worksheets are provided wherever possible to help you hit the ground
running with your new knowledge. To assist you in expanding your knowledge, I’ve taken
the liberty of providing lists of references (along with my personal ratings) at the end of
1
In troducfion
each major section of the book. Even the chronological order of presentation is intended
to convey the sense of a journey; from the soft and fuzzy world of conceptual design to the
final traumatic birthing process that characterizes the transition of new products into
production.
Well, the tour is about to leave the station (or terminal, or dock ...c hoose whatever
fantasy you wish). As you board, take a quick look at the summary of lean design tools
provided in the two figures that accompany this introduction. The Lean Design Tool
Quick-Reference Guide lists all eighteen tools, with a brief synopsis of each tool’s applica-
bility and an indication of where in the book it is described. The Timeline for Application
of Lean Design Tools suggests the periods within a typical product development process
during which each tool would be most beneficial. Naturally, your situation may be differ-
ent from the “typical.” Hence, these tools are designed to be flexible, scalable, and easily
adaptable. I’ll be providing hints on how to tailor them to your specific needs at every stop
along the way.
Welcome to the world of lean design. I hope you enjoy your intellectual journey, but
make no mistake: Your travels will be wasted if you don’t commit yourself to putting the
tools you’ve learned to work!
2
Lean Design Tool Quick-Reference Guide
Lean Design Tool Overview Section
Product Opportunity Ranking Tool Enables rapid prioritization of new product opportunities. 1.4
Target Costing Establishes a clear cost target for design teams early in development. 1.5
Twenty-C ost-Lev er Tradeoff Tool Tradeoff tool for comparing potential cost-reduction design alternatives. 1.6
Lean QFD Method for capturing the “voice of the customer” with minimal time and effort. 2.1
Must / Should / Could Prioritization Technique for the priority ranking of product specifications and features. 2.2
Product-Line Optimization Team An ad hoc team dedicated to identifying cross-product-line cost-savings. 3.1
Product-Line Roadmap A visualization tool that displays future line extensions, opportunities, etc. 3. I
Platform Plan A project plan for implementing platform-based cost-saving initiatives. 3.2
Module-Optimization Checklist Provides development teams with a way to optimize their platform designs. 3.3
Quick-Look Value Engineering Event Powerful tool for identifying and screening possible low-cost design options. 4.2
Pugh Method for Concept Selection A quick and easy method for evaluating several product design concepts. 4.3
Lean Design Challenge Harnesses the “smarts” of an entire organization to solve cost problems. 4.3
”How’s it Built?” Review A producibility review that brings together product and prcjcess designers. 5.3
“Seven-Alternatives” Process Optimizes capital investment by considering multiple process alternatives. 5.4
Cost-of-Poor-Quality Calculator A template for calculating the benefits of increasing process “capability.” 6.2
Six-Sigma Cost-Reduction Guide Overview of Six-Sigma Design tools with a focus on their cost-saving impact. 6.2
Design “Best-Practice’’ Guideline Template for capturing successful design techniques and cost-saving rules. 6.3
Lean Design “Maturity Model” A guide to the staged implementation of lean design tools within a firm. 6.4
Timeline for Application of Lean Design Tools
I I I
Project Conceptual Concept Detailed Qualification Production
Lean Design Tool
Selection Design Validation Design & Pilot Mfg. Launch
Product Opportunity Ranking Tool
Target Costing
Twenty-Cost-Lever Tradeoff Tool
Lean QFD
Must / Should / Could Prioritization
Product-Line Optimization Team
Product-Line Roadmap
Platform Plan
Module-Optimization Checklist
Quick-Look Value Engineering Event
Pugh Method for Concept Selection
Lean Design Challenge
“How’s it Built?” Review
”Seven-Alternatives Process
”
Cost-of-Poor-Quality Calculator
Six-Sigma Cost-Reduction Guide
Design “Best-Practice” Guideline
Lean Design “Maturity Model”
- Table of Contents
Ac k now 1e dgment s ii
Introduction - About This Guidebook 1
-
Part I The Business of Lean Design
Section 1.1 - Ground Rules and Basic Tools 7
Section 1.2 - What’s ccI,ean”M ean? 15
Section 1.3 - When Is a Product Profitable? 21
Section 1.4 - Screening for Profitable Projects 33
Section 1.5 - Defining a Target Cost 43
Section 1.6 - Twenty Levers for Product Cost 51
-
Part II Consider Cost From the Very Beginning
Section 2.1 - Capturing the Voice of the Customer 67
Section 2.2 - Prioritizing Customer Requirements 79
-
Part III Reducce Cost Through Cross-Product Synergy
Section 3.1 - The Product Line as a “System” 95
Section 3.2 - Platforms Come in All Sizes 107
Section 3.3 - Modular, Scalable, and Mass Customizable 11 7
-
Part IV Cost Leverage Is Greatest During Conceptual Design
Section 4.1 - Value Engineering and Analysis 137
Section 4.2 - The Quick-Look Value Engineering Event 145
Section 4.3 - Sponsoring a Design Challenge 175
-
Part V Preparing for Production: The ‘3P” Process
Section 5.1 - What’s a Lean Factory Look Like? 191
Section 5.2 - Overview of Toyota’s 3P Process 195
Section 5.3 - The “How’s it Built?” Review 201
Section 5.4 - The “Seven-Alternatives” Process 21 1
-
Part VI Attack Direct Costs During Detailed Design
Section 6.1 - What’s a Process Capability? 22 7
Section 6.2 - Six-Sigma /Robust Design 235
Section 6.3 - Design for Manufacture and Assembly (DFMA) 267
Section 6.4 - Achieving Continuous Cost Improvement 281
Conclusion - A W ord About Lean and Green 29 1
GI ossa ry 293
Bib 1 iograph y 303
Index 30 7
Part I
The Business of Lean Design
-
1.1 Ground Rules and Basic Tools
-
1.2 What’s “Lean” Mean?
-
1.3 When Is a Product Profitable?
-
1.4 Screening for Profitable Projects
-
1.5 Defining a Target Cost
-
1.6 Twenty Levers for Product Cost
5
Part I
-
‘Rule Number
1
Never lose money.
-
Rule Number
2
Never forget Rule Number I.”
Warren Buffett
“Where profit is,
loss is hidden near by.”
Japan es (7 Pro verb
“Most of us don’t recognize
opportunity until we see it working
for a competitor.”
Jay Huenfeld
6