The Lean Design Guidebook describes eighteen powerful and practical tools for product development teams that enable dramatic manufacturing cost reduction. The emphasis is on team activities that can create breakthroughs in material, labor, and overhead cost, while maintaining the highest quality and value for customers. An integrated approach to the application of these waste-eliminating tools is described, along with proven methods for training and deployment within a single team, or an entire organization. This is a highly readable book for practitioners in all fields related to product design and development, including design team members, team leaders, managers, and organizational improvement champions. The book makes extensive use of graphics (over 150 figures and diagrams) and is rich with real-world examples and step-by-step descriptions. A bibliography, a comprehensive glossary, and an index are provided.
Content:
Front Matter
• Table of Contents
• Introduction: About This Guidebook
•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
•Part II. Consider Cost from the Very Beginning
2.1 Capturing the Voice of the Customer
2.2 Prioritizing Customer Requirements
•Part III. Reduce Cost through Cross-Product Synergy
3.1 The Product Line as a "System"
3.2 Platforms Come in All Sizes
3.3 Modular, Scalable, and Mass Customizable
•Part IV. Cost Leverage is Greatest during Conceptual Design
4.1 Value Engineering and Analysis
4.2 The Quick-Look Value Engineering Event
4.3 Sponsoring a Design Challenge
•Part V. Preparing for Production: The "3P" Process
• 5.1 What's a Lean Factory Look Like?
5.2 Overview of Toyota's 3P Process
5.3 The "How's it Built?" Review
5.4 The "Seven-Alternatives" Process
•Part VI. Attack Direct Costs during Detailed Design
6.1 What's a Process Capability?
6.2 Six-Sigma/Robust Design
6.3 Design for Manufacture and Assembly (DFMA)
6.4 Achieving Continuous Cost Improvement
• Conclusion
• Glossary
• Bibliography
Index
• Biography