Lean Product Development Fundamentals
The 4-day course covers topics related to tools and techniques (TT) for Concurrent Engineering (CE) and Concurrent Product Development. The course provides examples of “how to define a collaborative workgroup and a concurrent work plan to reduce product development time?”; “how to establish a collaborative work-team for bringing product to market in half-the-time?” and “how to achieve significant cost savings via lean tools and best practices?” A number of case-histories on concurrent engineering with product break-down structures — all derived from system thinking + lean principles will be discussed.” You will learn:
- Fundamental techniques and concepts of Concurrent Enterprising (CE), Systems engineering (SE), Lean product development (LPD), and knowledge-based engineering (KBE),
- Key performance indicators (KPIs) for measuring the world-class competitiveness challenges,
- Strategic / proven techniques for bringing new products to market faster,
- How to assess your company’s strengths & weaknesses via Value Stream Mapping (VSM) and Process Reengineering and,
- How to overcome common bottlenecks and eliminate major risks?
From the hands-on exercises, you will learn what tasks/ jobs you are doing well, which tasks you need to eliminate, reengineer, or automate to reduce your development time, costs, and how to manage resources optimally? From the case-histories, you will learn how some of the advanced companies are using those concepts for capturing their product design-intent; how they are parametrically detailing their parts; integrating their designs with analysis; developing linked-assembly; and performing system-level optimization? Instructor will be demonstrating such concepts on some of the newer PLM tools such as Dassault system’s CATIA V5 and/or Pro-Engineer Creo-3 CAD tools. Instructor will also discuss some of the challenges and risks in CE, LPD, and limitations of the exiting CE/LPD tools; how to handle complexity of the products & processes, especially for safety oriented aerospace and space systems/ applications that are often multidisciplinary. Importantly, what precautions to take during early phases to avoid fixing problems later in their life-cycle? Comprehensive course notes will be provided, as well as copies of the key papers and case-reports.
This course can also be delivered as a 5-day offering to allow time for more discussion.
What you will learn:
- Learn techniques and concepts of achieving engineering and manufacturing excellence through the implementation, application and management of Concurrent Enterprising (CE).
- Discover exactly how concurrent enterprising has helped manufacturers and suppliers achieve stunning results in slashing design and production time/costs, while increasing product quality.
- Gain an understanding of the barriers of CE and how to reduce/ overcome them. Learn how to reduce product cycle time and shrink time-to-market.
- Discover how to increase customer satisfaction and market share. Identify how to minimize or manage engineering change orders and/or eliminate reworks.
- Learn how to handle cooperative versus adversary situation in a team setting. You will also learn principles of DFA/DFM for parts reduction and assembly, principles of designing Statistical Experiments and Robust Design.
- Design for X-ability concepts (e.g., DFM, DFA, DFS, etc.). Discover how to ensure “quality by design” as opposed to quality-inspection at the end-of-the-line.
- Best strategies for selecting staffing and managing multi-disciplinary functional project-teams.
Course is designed for:
- Enterprise and IT managers
- Systems engineers
- Technical team leaders
- Program managers, directors
- Project managers, directors
- Logistic support leaders, Schedulers
- Design/Analysis engineers,
- Others who participate in defining and developing complex systems.
- Manufacturing Competitiveness: Review of Historical Events, Push and Pull for New Paradigms, Areas of Manufacturing Competitiveness; Products and Services, Process and Methodologies, Key Performance Indicators, CE Infrastructure, Example Problems.
- Life-Cycle Management: Shrinking life-Cycle, Life-Cycle Management, New Product Introduction, Strategic Technology Insertions, Managing Continuity, Managing Revision Changes, Life-Cycle Cost Drivers, Life-Cycle Management Tools, Sequential versus Concurrent Engineering, Test Problems.
- Process Re-Engineering: Understanding and Managing Change, Reengineering Approaches, Tenants of Process Improvements, Work-Flow Mapping, Information Flow-Charting, Enterprise Models, Process Improvement Methodologies , Change Management Methodologies, Concurrent Process Reengineering, Salient Remarks, Examples.
- Concurrent Engineering Techniques: Basic Principles of CE, Components of CE, Concurrency and Simultaneity, Modes of Concurrency, Modes of Cooperation, Benefits of Concurrent Engineering, Test Problems.
- Cooperative Work-Groups: Cooperative Concurrent Teams, Program Organization, Supplier Rationalization, Types of CE Organizations, Management Styles or Philosophies, Workplace Organization and Visual Controls, Employee Excellence Development (New Technologies and Team Capabilities), Example Problems.
- Systems Engineering: An Automobile Manufacturing Process, System Engineering, Systems Thinking, Approaches to System Complexity, Sharing and Collaboration in CE, System Integration, Management and Reporting Structure, Agile Virtual Company, Test Problems.
- Information Modeling: Information Modeling, Modeling Methodologies, Foundation of Information Modeling, Concurrent Engineering Process Invariant, Enterprise Model-Class, Specification Model-Class, Product Model-Class, Process Model-Class, Cognitive Models, Merits and Demerits, Example Problems.
- The Whole System: Conventional Design and Development Process, Transformation Model for a Manufacturing System , CE Enterprise System Taxonomy, Integrated Product and Process Development, Transformation System for Product Realization, Key Dimensions of a CE Specification Set, Artifact’s Intent Definitions, Test Problems.
- Product Realization Taxonomy: Concurrent Product Realization Taxonomy (CPRT), Development Methodology for CPRT, Pull System of Product Realization, Description of Parallel Tracks, Description of 2-T Loops, Description of 3-T Loops, Major Benefits, Example Problems
- Case Histories: Practical application of the concurrent/ systems engineering. Examples of concurrent and efficient system models for designing, developing, and building variety of products and systems. Concurrent Engineering (CE) Wheel Two (2): Topics on Integrated Product Development
- Concurrent Function Deployment: Components of QFD, Limitations in Deploying QFD, Concurrent Product Development, Concurrent Function Deployment (CFD), CFD Methodologies, Applications of CFD, Formulation of CFD as an Optimization Problem, Horizontal Deployment, CFD Tier-based Vertical Deployment, Implementation Issues, Test Problems.
- CE Metrics and Measures: Metrics of Measurements, Establishing Life-cycle CE Measures, Value Characteristic Metrics (VCM), Simulations and Analyses, Product Feasibility and Quality Assessment, “Design for X-ability” Assessment, Process Quality Assessment, VCM Management, Example Problems:
- Total Value Management: Total Quality Management (TQM), Total Value Management (TVM), Methodology for TVM, Major Elements of TVM, TVM in the Product Development Process, TVM Measures of Merits, Value Management Tools, Concurrent Process for TVM, TVM Measures, Test Cases.
- Integrated Product Development (IPD) Methodology: IPD Process Invariants, Integrated Product Development Process, Steps in IPD Methodology, Product Requirements Planning and Management, Work Structuring and CE Team Deployment, Methodology Systemization, Product and Process Systemization , Problem Identification and Solving Methodologies, Integrated Problem Formulation, Collaboration and Cross-functional Problem Solving, Continuous Monitoring and Knowledge Upgrade, Concurrent IPD Methodology, Test Problems
- Frameworks and Architectures: General Frameworks/Architectures, Distributed Computing, Work Group Computing, Product Information Management (PIM), Examples of CE Architectures, CE Sub-architectures, CE Computational Architecture, Standards, Test Problems.
- Capturing Life-Cycle Intent: Design Classification, Life-cycle Capture, Languages for Life-cycle Capture, Capture Product Models, Creation of Smart or Intelligent Models, Examples of Smart or Intelligent Models.
- Decision Support Systems: Basis of Decision Making, Typical Progressive Models, Intelligent Models, Smart Regenerative System, Life-cycle Values, Total Life-cycle Cost, Compatibility Analysis, Sensitivity Analysis, Life-cycle Ranking or Rating Scheme (LCRS).
- Intelligent Information System (IIS): Enabling Elements of IIS, Major Barriers, Vision of the Future, Levels of Intelligence, Product Intelligence, Process Intelligence, Technical Memory, Flexible Computer Integrated Manufacturing (FCIM). Groupware, Test Problems.
- Life-Cycle Mechanization: CE Mechanized Environment, Concurrent Product Development (CPD), CE Network Tools and Services, IPD Automation Modules (Preprocessing), IPD Automation Modules, Library of Parts, Synthesis Models, Decision Support Tools or Models, Knowledge-based Product and Process Models, Computer-based Training Tools, Cost and Risk Reduction Tools, IPD Automation Modules (Post-processing), Unified or Single PPO Concept, Test Problems.
- Implementation Guidelines: IPD Deployment Mythology, Strategic CE Ideals, Ten Commandments of IPD Deployment, CE Case Histories, Computation of Enterprise Savings, Risks Assessments.
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Dr. Brian Prasad is President and CEO of Knowledge Solution, a Product Life-cycle Management (PLM) service company. He is a senior executive consultant, chief knowledge officer and served as Advisors to many large fortune 500 companies including Panasonic Avionics, Parker Aerospace, General Motors, Ford,, Unigraphics/NX Solution, DS/CATIA, and HP/EDS. He is the editor-in-chief of the Concurrent Engineering: Research & Applications – a journal of international fame/reputation now entering 23rd years of its consecutive publication. He has written many books on concurrent/system engineering, lean subjects and has published numerous papers (over 150) in many refereed journals and conferences. https://www.researchgate.net/profile/Brian_Prasad/contributions?ev=prf_act He is a well-recognized industry expert in concurrent engineering, lean product development (LPD) and system engineering (SE). He is widely known in the concurrent, LPD and SE circles. He is the Fellow of ASME. He has served on many lean committees for ASME, SAE, ASCE and AIAA organizations. He is a graduate of Stanford University, CA and Illinois Institute of technology, Chicago. He received his Ph.D. in Mechanical and Aerospace Engineering.
Dr. Prasad is an Editor-in-Chief for Institute of Concurrent Engineering, Tustin, USA. Concurrent Engineering: Research and Applications (CERA) provides quality articles on all aspects computer-aided concurrent engineering (CE). The journal deals with all basic tracks that enable CE, including: information modeling, teaming & sharing, networking & distribution, planning & scheduling, reasoning & negotiation, collaborative decision making, and organization and management of CE. This journal is a member of the Committee on Publication Ethics (COPE).