Lean Product Development: Online

• Understand key deference between traditional and lean product development
• Understand and apply lean thinking methodology
• Evaluate and critically assess current and future level of lean practices in an organisation
• Improve innovation through implementation of set-based concurrent engineering
• Understand and apply design for manufacturing and assembly methods
• Understand and apply A3 thinking for design problem-solving
• Understand and apply lean knowledge life-cycle approach to systematically capture, re-use and create knowledge in product development
• Understand and apply trade-off curves to visualise PD knowledge and generate a set of conceptual solutions
• Introduce LeanPD practices in your organisation

Module 1 - Fundamentals of Product Development and Concurrent Engineering

• To present different approaches in product development and some of the most common challenges faced in this stage of product life-cycle.
• To introduce the concept of concurrent engineering as a multi-disciplinary approach of simultaneous product and process design. It also covers the multi-disciplinary team formation.

Module 2 – Traditional Product Development Tools and Methods: QFD, DFM, DFA, FMEA, Pugh Matrix

• To present a view of the interrelations among the different traditional PD tools and methods such as Quality Function Deployment (QFD), Failure Mode and Effects Analysis (FMEA), Design for Manufacturing and Assembly (DFMA) as well as Pugh Matrix.
• To describe the Design for Manufacturing (DFM) method and its role in ensuring the manufacturability of the component in shorter time and lower cost. It covers DFx where x is one of the different manufacturing processes such as injection moulding, casting, machining, welding, stamping, etc. The participants will perform DFM exercises using real engineering examples.
• To describe the Design for Assembly (DFA) principles and method. In addition its role in designing a product with less components and ensuring manufacturability and assembly in shorter time and leas cost. The participants will perform DFA exercises using real engineering examples.

Module 3 – Fundamental of Lean Product Development and Set-Based Concurrent Engineering (SBCE)

• Lean product development is an approach originating from Toyota’s Product Development System (TPDS) where focus is shifted from waste elimination to value creation. This session aims to introduce the foundations of Lean PD and its core enablers LeanPD performance measurement, set-based concurrent engineering, Lean Knowledge Life Cycle, A3 Thinking and Trade-Off Curves.
• Set-Based Concurrent Engineering is lean thinking methodology that enhances PD performance and increases its productivity and innovation. This session aims to introduce the principles and key activities of SBCE process model. In addition, different tools and methods to support SBCE will be presented and demonstrated through two detailed case studies from aerospace and security industry.

Module 4 - Lean Knowledge Life Cycle and A3 Thinking for Design Problem-Solving

• This session is to present the LeanKLC which is a methodology which enables companies to systematically capture, re-use and create knowledge in product development.
• To introduce the A3 thinking methodology for product design problem-solving based on the learning cycle of PDCA and LAMDA. Several industrial cases from will be discussed to demonstrate the power of the knowledge capture and visualisation in simple manner.

Module 5 – Trade-off Curves to enable SBCE

• The session is to introduce ToC as a knowledge visualisation tool which enable SBCE applications through generating sets of designs, comparing different design solutions, narrowing sets of design solutions, and optimising final design solution.

Module 6 – Group Project: SBCE Application of Developing an Office Chair

• To work in a group and to have hands-on experiences and a flavour of the application of SBCE through interactively exercise of developing an office chair