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Blog - Lean Practices in Product Development Engineering

For Momentum Blog
by

Ray Minato

on 25 September 2014

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Transcript of Blog - Lean Practices in Product Development Engineering

thinking
We provide engineering, product development and consulting services, from concept to production, that deliver exceptional customer experiences and results.
inertiaengineering.com
So you're probably asking yourself...
What does Inertia know about lean?
Fair Question
...so let's back up a bit
...a refreshing approach
Injection Moulding Manufacturing
Where we started
Demanding Customers
Demanding Products
Motorsports Engineering
Toyota Production System
Motorsports Design
How do you say kaizen in Italian?
Elimination of Waste
- handling / limitations in grip
- driver error / driver effort
- optimal use of power (gearing)
Industrial engineering at its finest...
Lean Practices in Product Development Engineering
PHILOSOPHY
METHODS
TOOLS
They probably read about it in a book...
Pull Production System
Time-Motion Studies
Levelized Production System
Visual Production Control
DISCIPLINE
Necessity, who is the mother of invention
CLIENT VALUE
PROFIT
Plato
Our Necessity...
engineering consulting
contract / outsource engineering

technical and situational analysis

process optimization

technology commercialization
product development
turn key product design

product concept generation

prototyping

manufacturing
design + engineering
project management

mechanical + electrical engineering

industrial design + styling

analysis + simulation

testing
Lean Practices in a Service Industry
What is lean?
elimination of waste

creating more value for customers with less resources
So what does it look like?
We took some of this thinking...
...and applied it to this services business
real
world
of processes and workflow





of documents by creating templates
Desire
What's your philosophy?
Collaboration
Communication
Continuous Improvement
Standardization
Automation
Concurrrent Engineering
Outsourcing
Product Data Management
On-line Project Management + Collaboration
Management
Truth + Accountability
Perseverence
You are our business and we are here to serve you
You have to want to do better...
WE
THINK
You should have great service
You should have great products
You should have peace of mind
We provide creative, collaborative and practical product development solutions
Our personable and professional staff ensure the job will be done right
DIFFERENTLY
You are our business and we are here to serve you
COLLABORATION
we involve our clients deeply in the design process at every step; they see the concepts as they are developed, understand all the options and buy-in to the solution

we play on a level plane where all team members have equal chance to bring forth and promote their ideas as well as challenge existing assumptions and thinking

we empower our team with the software tools to more easily and efficiently collaborate their design ideas
COMMUNICATION

daily internal meetings with staff

Constant Client Contact: we communicate our ideas through visual presentations via the web or face to face meetings

Transparency: we maintain all our project plan and task lists on-line which is available for our clients to see anytime, what is happening as though we were working in the same office
CONTINUOUS IMPROVEMENT

Lessons: we take time to learn from our mistakes and successes
Deliberately schedule time to train, refine and reflect
What's your philosophy?
We call it...
real
world
thinking
STANDARDIZATION
AIAG APQP
Workflow Control of Documents
AUTOMATION
templates






workflow
Electronic Review, Approvals and Release
Batch file processing
CONCURRENT ENGINEERING
Traditional Product Development
Concurrent Engineering Approach to PD
More than 1,470,000 product designers and engineers worldwide, representing 141,200 organizations use SolidWorks.

Solidworks showcases IE+D as an industry leader in the use of Solidworks design, simulation and data management
Manufacturing
Design
Simulation
Drawings
Manufacturing
Design
Simulation
Drawings
OUTSOURCING
...we designed and engineered this in just 8 weeks
...50% faster than
traditional methods
The Result
IE+D uses off-shore engineering + design support in China

Benefits
reduced cost
responsiveness (off-shift capacity)
workforce size flexibility
focus on strengths
...the result is almost 50% reduction of cost
Challenges
takes time to setup a team, systems and protocol
use for certain kinds of work (drawings / reverse engineering) - low collaboration
trust, legal documents and protocol must be established to ensure IP is secure
PRODUCT DATA MANAGEMENT
IE+D uses Solidworks PDM database to manage all documents

key enabler for collaboration + concurrent engineering
everyone uses the same information (no local copies)
automatically bill of materials for design assemblies
version / revision control
data entry and batch file automation
history / traceability of document revisions
ECO / release workflow control
meta-data can be transferred to ERP systems
all documents saved in SQL vault
PDM is the backbone of our business
ONLINE PROJECT MANAGEMENT + COLLABORATION
IE+D uses Zoho and GoogleDocs on-line project management applications:

Functions
project + task planning
concurrent sharing / editing of documents
real-time dashboard status updates of projects
team on-line chat
web meeting capability
e-mail integration
on-line hosted software - accessible anywhere (the internet is)




On-line Project Management + Collaboration Benefits

project plans are deployed quickly and efficiently
project plans are viewed by all - team sees the big picture + milestones
directives are explicit and public
team mentality is reinforced (jump on the grenade)
accountability is obvious - there is no hiding
visual management helps to keep the finger on the pulse
works well for dispersed team (eg. offshore)
Some examples of on-line pm applications:
this project was completed ~30% faster because of the PDM collaboration capabilities
MANAGEMENT
Keep it short and to the point

Daily Huddles
15' long
standing up
what have you done since yesterday?
what will you get done today?
do you have any problems that will prevent you from accomplishing your goal?

Weekly Meetings
45' long
Good news: personal + business
Review last weeks numbers
Top 3 priorities to accomplish for the week
Customer updates
One word close
TRUTH +
ACCOUNTABILITY
At the end of the day, you have to do what you say your going to do.

When things get off track - address it immediately by using a
technique called the Managerial Moment of Truth

It's a way of telling the truth and getting to the bottom of an
issue without hurting people. The technique has four steps:

Acknowledge the truth
Analyze how it got to be that way
Create and action plan
Establish a feedback system
PERSEVERENCE
DON'T EVER GIVE UP
...these are techniques pulled straight out of
Thank you for listening to
Lean Practices in Product Development Engineering
Do you have any questions?
Thank you for reading!
Elimination of Waste = More Power
reduction of aerodynamic drag
reduction of weight
reduction of friction
First, a little background on what we do....
Full transcript