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Lean Product Development

Eric Rebentisch

October 5, 2005

Lean Engineering Learning Points

• Lean applies to engineering

• Lean engineering process eliminates waste,


focuses on value creation, and improves cycle time
• Efficient and standard process enables better
engineering
• Integrated Product and Process development (IPPD)
and other tools are critical for lean enterprise

ESD.61J / 16.852J: Integrating the Lean Enterprise Page 2 © Eric Rebentisch, 2005
Lecture #8: October 05, 2005 Massachusetts Institute of Technology
Lean Engineering Enables

Faster and More Efficient Design

Forward Fuselage Development Total IPT Labor

Prototype EMD Wireframe


Wireframe with 2D Drawing
Release Release
Results from vehicle of
Prototype approximate size and work
3D Solid content of forward fuselage
Release

Staffing
Level

Prototype
3D Solid
Release - 2000 *

Months from End of


Source: “Lean Engineering”, LAI Lean Academy™, V3, 2005 Conceptual Design Phase
Source: “Lean Engineering ”, John Coyle (Boeing), LAI Executive Board Presentation, June 1, 2000

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Lecture #8: October 05, 2005 Massachusetts Institute of Technology
Lean Engineering Improves
Manufacturing
Additional Reduction in T1 via
Virtual Mfg. of Approx. 9 Units

Before Lean Engineering


After Lean Engineering
Mfg.
Labor
(hrs) Reduction in
Work Content via
76% Slope Improved Design

48% Savings

83% Slope
0
-10 -5 1 5 10 15 20 25 30 35
Source: “Lean Engineering”, LAI Lean Academy™, V3, 2005
Production Units
Source: “Lean Engineering ”, John Coyle (Boeing), LAI Executive Board Presentation, June 1, 2000
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Lecture #8: October 05, 2005 Massachusetts Institute of Technology
Using Efficient Engineering Processes:

Applying lean thinking to eliminate wastes and improve cycle

time and quality in engineering

• Effort is wasted
pure value • 40% of PD effort “pure waste”, 29%
waste added “necessary waste” (workshop opinion
survey)
necessary • 30% of PD charged time “setup and
waste waiting” (aero and auto industry survey )

• Time is wasted
task • 62% of tasks idle at any given time
(detailed member company study)
active
task • 50-90% task idle time found in Kaizen-
idle type events

Source: McManus, H.L. “Product Development Value Stream Mapping Manual”, LAI Release Beta, April 2004
Source: “Lean Engineering”, LAI Lean Academy™, V3, 2005

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Lecture #8: October 05, 2005 Massachusetts Institute of Technology
What is Product Development?

“The
“Theset
setof
ofactivities
activitiesbeginning
beginningwith withthe theperception
perceptionof ofaamarket
market
opportunity
opportunityand andending
endingin inthetheproduction,
production,sale saleand
anddelivery
deliveryof ofaa
product”.
product”.Ulrich
UlrichK.
K.and
andEppinger,
Eppinger,S,S,Product
ProductDesign
Designand
andDevelopment,
Development,McGraw-Hill,
McGraw-Hill,1995
1995

Concept Engineering & Manufacturing Production


C Development Development C
U CUSTOMER
CUSTOMER U
REQS
S REQS
S
T RFP
CONTRACT DESIGN DESIGN T
O O
M PROPOSAL BUILD
FABRICATE M
DESIGN
E PACKAGE E
ASSEMBLE
R VERIFY
R
DELIVERED
SHIP PRODUCT

Source: Adapted from Aerojet General Corporation Briefing- “ Value Stream Analysis
Applied to the Product Development Process”
ESD.61J / 16.852J: Integrating the Lean Enterprise Page 6 © Eric Rebentisch, 2005
Lecture #8: October 05, 2005 Massachusetts Institute of Technology
Lean Engineering:

Doing the Right Thing Right

•• Creating
Creating the
the right
right products…
products…
•• Creating
Creatingproduct
productarchitectures,
architectures,families,
families,and
anddesigns
designsthat
that
increase
increasevalue
valuefor
forall
allenterprise
enterprisestakeholders.
stakeholders.
•• With
With effective
effective lifecycle
lifecycle && enterprise
enterprise integration…
integration…
•• Using
Usinglean
leanengineering
engineeringto
tocreate
createvalue
valuethroughout
throughoutthe
the
product
productlifecycle
lifecycleand
andthe
theenterprise.
enterprise.
•• Using
Using efficient
efficient engineering
engineering processes.
processes.
•• Applying
Applyinglean
leanthinking
thinkingtotoeliminate
eliminatewastes
wastesand
andimprove
improve
cycle
cycletime
timeand
andquality
qualityin
inengineering.
engineering.
Source: McManus, H.L. “Product Development Value Stream Mapping Manual”, LAI Release Beta, April 2004
Source: McManus, H.L. “Product Development Value Stream Mapping Manual”, LAI Release Beta, April 2004

Framework based upon a decade of Lean Aerospace

Initiative research and industry/government implementation

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Lecture #8: October 05, 2005 Massachusetts Institute of Technology
One Approach: Value in PD Emerges

Through Uncertainty Reduction

Activities accumulate information, eliminate risk, use resources

Risk Process
Info Outcome

Value
Value

Realized

Time
Adapted From Chase, “Value Creation in the Product Development Process”, 2001.

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Lecture #8: October 05, 2005 Massachusetts Institute of Technology
A Framework for Reducing Uncertainty in

PD

Risks/ Mitigations/
Uncertainties Opportunities Exploitations Outcomes
• Disaster
• Margins
• Lack of Knowledge • Failure • Reliability
• Redundancy
• Lack of Definition • Degradation • Robustness
• Design Choices
• Statistically • Cost/Schedule (+/-) • Versatility
Characterized • Verification and Test
• Market shifts (+/-) • Flexibility
Variables • Generality
• Need shifts (+/-) • Evolvability
• Known Unknowns • Upgradeability
• Extra Capacity • Interoperability
• Unknown Unknowns • Modularity
• Emergent
• Tradespace Exploration
Capabilities
• Portfolios&Real Options

<Uncertainty> causes <Risk> handled by


<Mitigation> resulting in <Outcome>

Source: HL McManus and Daniel Hastings, Presentation at INCOSE 2005 - Rochester NY, July
2005

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Lecture #8: October 05, 2005 Massachusetts Institute of Technology
Value Measurement

• EVMS is commonly a common measure of “value” in PD


• Typically generated from WBS at project launch
• Relationship to underlying processes varies
• Level of detail can make it difficult to get program-level
perspective on state of work completed, in-process, waiting, or
otherwise in play

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Lecture #8: October 05, 2005 Massachusetts Institute of Technology
Waste Drivers – The Causes of Waste

Large information
Handing task over
Main Categories of Waste Drivers buffers
to colleague

Inventory

Handoffs
A
Waiting

Reinvention
… and 6 other
Engineers waiting
for data

Poor knowledge reuse


… and 36 other
Source: Christof Bauch, Lean Product Development enabling display: Making waste

transparent, TUM Thesis 2004

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Lecture #8: October 05, 2005 Massachusetts Institute of Technology
Complete Framework for Causes of Waste in
Product Development
Exceeding capacity
utilization

Unnecessary detail and Use of inappropriate tools/ High system variability


accuracy methods
Lack of direct access
Large batch sizes
Unnecessary features and Excessive approvals
processes
Queues on the critical path
Remote locations Excessive transactions
Inappropriate use of
competency
Unnecessary testing
equipment and prototypes
Excessive data traffic Information hunting Obvious Waste drivers
- Sub-categories -
Excessive data storage
Handoffs

4 Over processing
Stop and go tasks/ Task
switching 3 Movement
5 Inventory Poor synchronisation as
Ineffective Communication regards time and capacity

Time
Obvious Waste drivers
Poor synchronisation as
Resources/Capacity - Main categories -
Waiting for data, answers, 2 Transport/ Handoffs Info/Knowledge
regards contents
specifications,
requirements, test results
approvals, decisions,
6 Overproduction/
Over-dissemination of
releases, review events, Waste Unsynchronized processes
information
signs
1 Waiting Quality Opportunity
Information is waiting for
Redundant tasks
people

Flexibility What can be wasted? 7


Waiting for capacity
available (human or
10 Defects
Limited IT resources
machine)
Deficient information
quality
8
9 Reinvention
Lack of system discipline
Poor compatibility Erroneous data and
information

Poor capability Poor testing and


verification
Incompetence/ poor
training
Low capacity Unclear goals and
objectives
Poor design re-use
Poor schedule discipline
Unclear roles,
responsibilities and rights
Insufficient readiness to Poor knowledge re-use
cooperate Unclear rules

Source: Christof Bauch, Lean Product Development enabling display: Making waste
transparent, TUM Thesis 2004
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Lecture #8: October 05, 2005 Massachusetts Institute of Technology
Tracking Waste in Programs Using

Swim-Lane VSM

#1 Rework
Task #1(5day)
(3day)
Group Task #1 (5day)
A Task #4
Task #4 (5day)

Task #6 (5day)

Hand-off
Group Task #2
B Task #2 (5day) Task #3
Task #3 (5day)

Task #5 (5day)

Source: Jin Kato, LAI Plenary presentation, March 2004


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Lecture #8: October 05, 2005 Massachusetts Institute of Technology
Making Processes Flow

ƒ Value Stream Mapping and Analysis required for understanding

ƒ Process mapping and Design Structure Matrix methods most


powerful for process improvement
ƒ Process mapping customized for PD developed

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Lecture #8: October 05, 2005 Massachusetts Institute of Technology
F-16 Lean Build-To-Package
Support Center PDVSM Results
Forward to
Operations initiates Log/ Hold in
Engrg Engr answer Prepare Forward To
Request for Action Backlog Design Change Planning

Operations
Forward to Uses
Operations Revised
Planning
Log/ Hold in Prepare Tool
Backlog Planning Change Affected?
Forward to Log/ Hold in
Prepare Tool Order Process Tool Order
TMP Backlog

Forward to Log/ Hold in Prepare Tool Forward to Log/ Hold in Complete Tool
Tool Design Backlog Design Change TMP Backlog Order Processing

Forward to Log/ Hold in Forward to


Complete Log/ Hold in Accomplish Forward to
MRP Backlog Tool Mfg..
Tooling BTP Backlog Tooling Change Operations

Operations
Uses
Revised
Tool

Process Before PDVSM

BTP Elements
Worked
849 BTP packages
Concurrently
Prepare
Design Change Category Reduction
Cycle-Time 75%
Prepare Operations
Operations initiates Req. BTP Integrator Planning Change Forward To Uses
Holds Operations Revised
Meeting
Prepare Tool BTP/Tool

Process Steps 40%


Design Change
(If Applicable)

Accomplish

No. of Handoffs 75%


Tooling Change
(If Applicable)

Travel Distance 90%


Process After PDVSM Source: “F-16 Build-T- Package Support Center Process”, Gary Goodman, Lockheed
Martin Tactical Aircraft Systems LAI Product Development Team Presentation, Jan 2000
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Lecture #8: October 05, 2005 Massachusetts Institute of Technology
PDVSM Used For Spacecraft
Mechanical Environmental Test
As-Is Process To-Be Process

Added
Value
Required
Waste
Time Time
Category Before After Reduction
Test Cycle Time 14.7 Days 8.6 Days 41%
Labor $1,687,908 $701,564 58%
Material $554,304 $132,864 76%
Travel Distance 85,560 Feet 7,200 Feet 92%

Critical path system test cycle time reduced by 6 days


Source:Lockheed Martin Missiles and Space Systems
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Lecture #8: October 05, 2005 Massachusetts Institute of Technology
Additional Tools of Lean Engineering

• Integrated 3-D solids-based design


• Design for manufacturing and assembly (DFMA)
• Common parts / specifications / design reuse

• Dimensional management
• Variability reduction
• Production simulation

Source: “Lean Engineering”, LAI Lean Academy™, V3, 2005

ESD.61J / 16.852J: Integrating the Lean Enterprise © Eric Rebentisch, 2005


Lecture #8: October 05, 2005 Massachusetts Institute of Technology
Design for Manufacturing & Assembly
Reduced F/A-18E/F Parts Count
Forward Fuselage Wings and
and Equipment Horizontal Tails
C/D Parts C/D Parts
5,907 1,774

E/F Parts E/F Parts


3,296 1,033

Center/Aft Fuselage,
Vertical Tails and Systems
C/D Parts
5,500
Total*
E/F Parts
C/D Parts E/F Parts
2,847
14,104 8,099
*Includes joining parts
NAVAIR Approved
for Public Release:
SP168.04
E/F 25% larger and 42% fewer parts than C/D CC84740117.ppt

ESD.61J / 16.852J: Integrating the Lean Enterprise © Eric Rebentisch, 2005


Lecture #8: October 05, 2005 Massachusetts Institute of Technology
Source: “Lean Engineering”, LAI Lean Academy™, V3, 2005
Multi-use Parts/Design Reuse

Made Symmetrical
Slat Spar 8X Multi-Use LH & RH Same
LH & RH Mirror

Slat Spar
Stiffener
3X Multi-Use
LH & RH Mirror
Made Mirror Image

2X Multi-Use LH & RH Pair Same


LH & RH Same

Slat Spar
Splices
Slat Spar Splices

• Fewer part numbers (so more of each) reduces part cost


• Same multi-use part reduces assembly variation
• Same symmetrical part reduces identification errors
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Lecture #8: October 05, 2005 Massachusetts Institute of Technology

Source: “Lean Engineering”, LAI Lean Academy™, V3, 2005

Dimensional Management Enabled by Key

Characteristics

Key Characteristics: Critical few product features that significantly


affect the quality, performance, or cost of the product

System KCs

Subassembly KCs

Feature KCs

Critical parameters that cannot withstand variation – thus causing


a loss (rework, scrap, repair, or failure) in fabrication / production.
Source: Anna C.Thornton, Variation Risk Management, John Wiley & Sons, Inc. 2004
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Lecture #8: October 05, 2005 Massachusetts Institute of Technology
Variability Reduction

Dimensional Management Statistical Process


in Product Development Control in
Key Manufacturing
• Coordinated datums and Characteristics
tools • Key processes
• Geometric dimensioning • Focus on the • Control charting
and tolerancing significant few
• Process capability • Process improvement
data • Feedback to design
• 3-D statistical modeling

Lean manufacturing requires robust designs and


capable processes!
ESD.61J / 16.852J: Integrating the Lean Enterprise © Eric Rebentisch, 2005
Lecture #8: October 05, 2005 Massachusetts Institute of Technology
Source: “Lean Engineering”, LAI Lean Academy™, V3, 2005
Integrated Product Team

FUNCTIONAL Team
REPS Leader

* Program Mgmt
* Engineering
* Manufacturing
Working
* Logistics together to:
* Test & Eval
•Contracting
•Suppliers ƒ Build successful programs
* User ƒ Identify and resolve issues
(All APPROPRIATE Areas)
ƒ Make sound, timely decisions
Source: “Lean Engineering”, LAI Lean Academy™, V3, 2005

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Lecture #8: October 05, 2005 Massachusetts Institute of Technology
RTCE Structure Based on ICE

Evolution of a Revolution
• ICE: “Integrated Concurrent
Engineering”
• Developed initially at JPL’s
Product Design Center in 1994
• Further enabled by creation of
ICEMaker© software at Caltech

• Not talking about the design,


but actually doing the work
together!
• All design information is passed
through a central server - each
designer has access to the
latest data and sees changes
instantly
Source: David Stagney, presentation at LAI Plenary Conference, March 2003

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Lecture #8: October 05, 2005 Massachusetts Institute of Technology
RTCE Team Context

Tremendous Success in the First 9 months!


• Completed at least 20 new product proposals this year
• Trimmed 33% lead time from their standard process
• Created new designs in as little as 4 hours – compared to up to
4 weeks previously
• Distinct Competitive Advantage in time-sensitive situations
• Higher quality designs are being produced

• More detail, earlier in process

• Sharing over 7000 design variables in real time

• Objective decisions

• Focus on System Design - no sub-optimization

• Efficient Process and Motivated Team

Source: David Stagney, presentation at LAI Plenary Conference, March 2003

ESD.61J / 16.852J: Integrating the Lean Enterprise Page 24 © Eric Rebentisch, 2005
Lecture #8: October 05, 2005 Massachusetts Institute of Technology
Emerging Vision of Lean PD

• PD process/state awareness and transparency


• Value-driven lean management metrics
• Flow and pull of Information and decisions
• Value stream mapping, improvement activities and
processes on a continuous basis

Built on foundation of stable, consistently executed


processes that are understood, assessed, and
continuously improved by their users

ESD.61J / 16.852J: Integrating the Lean Enterprise Page 25 © Eric Rebentisch, 2005
Lecture #8: October 05, 2005 Massachusetts Institute of Technology
Creating the Right Products:
Creating product architectures, families, and designs
that increase value for all enterprise stakeholders.
LCC committed
100% “Fuzzy
“FuzzyFront
FrontEnd”
End”
80% Challenges
Challenges
Cost Incurred
Understanding
Understandingwhat
whatthe
the
66%
customer
customervalues
values
Ease of Change Deciding
Decidingwhich
whichproduct
productto
to
pursue
pursuefrom
fromamongst
amongst
Conceptual/ Detail Production Product use/
many
manyopportunities
opportunities
preliminary design/ and/or support/
Design development construction phaseout/dispos al Selecting
Selectingthe
theright
right
Source: Fabrycky & Blanchard product
productconcept
concept

Early
Earlydecisions
decisionsare
arecritical
critical--Disciplined
Disciplinedlean
lean
systems
systemsengineering
engineeringprocess
processisisessential!
essential!
Source: McManus, H.L., Allen Haggerty, Earll M. Murman, “Lean Engineering: Doing the Right Thing Right”, presentation
at 1st International Conference on Innovation and Integration in Aerospace Sciences, August 5, 2005
ESD.61J / 16.852J: Integrating the Lean Enterprise Page 26 © Eric Rebentisch, 2005
Lecture #8: October 05, 2005 Massachusetts Institute of Technology
Military: Software
Development Value Stream(s)
10101010
OFP Value Stream 1010010
01010...
Delivered
Documentation (Technical Orders) Product
Concept Development

Government Certification

Support Equipment Software Changes

Multiple Aircraft Sensor Software Changes

Multiple Weapons Software Changes

Weapons & Tactics Trainers


Source: Brian Ippolito, “Identifying Lean Practices for Deriving Software
Requirements”, MIT Master’s Thesis, February 2000
ESD.61J / 16.852J: Integrating the Lean Enterprise Page 27 © Eric Rebentisch, 2005
Lecture #8: October 05, 2005 Massachusetts Institute of Technology
Framework For Effective Front-End Process

Identification Process Flow


Feedback
Screening
Concept
Development
Business Case
Development
Best
BestPractices
Practices
Identification Screening Concept Business Case
Small multidisciplinary Senior level decision Requirements given as Clear, concise product
teams variables within concept, architecture
Active portfolio
desired range and concept of
Adequate funding management
employment
Team remains intact
Multiple requirements Strategic plan and
throughout process Based upon:
ID methods used resource constraints
• Product lifecycle
guide prioritization Data driven tradeoff
Independent strategy
analysis - use of
assessment of • Fit with product
prototypes
solution portfolio
• Returns to
organization
Closure
Closure ofof Technical
Technical AND
AND Business
Business Case
Case isisMandatory
Mandatory
ESD.61J / 16.852J: Integrating the Lean Enterprise Page 28 © Eric Rebentisch, 2005
Lecture #8: October 05, 2005 Massachusetts Institute of Technology
Source: J. R. Withlin, “Best Practices in User Needs/Requirements Generation”, MS Thesis, MIT 1994
Company A’s Front End Process

Front-End Process Flow Business Case


Requirements Initial Concept Development /
Identification Screening Development Final Screen

Business
Market & Program
Business Commercial Plan
Initiation
Need, Research
New Ideas, Request
Technology
Developments Technical
Research
Feasibility Senior
Screening Phase Committee
Committee

Product Product
Operational
Proposal Launch
List
List List

Lists maintained by Program Management for the committees

ESD.61J / 16.852J: Integrating the Lean Enterprise Page 29 © Eric Rebentisch, 2005
Lecture #8: October 05, 2005 Massachusetts Institute of Technology
Source: J. R. Withlin, “Best Practices in User Needs/Requirements Generation”, MS Thesis, MIT 1994
Performance of Company A’s Front End

Process

• Single high-level Screening Committee (~7 members, VP level)


• Oversees both R&D and planning processes across company
• Approves Program Initiation Requests (PIRs) and commits company
funding ($300M-$1B authority—for reference: 1999 annual sales $2.7B)
• Work in process (annual):
• ~100 concept solutions considered
• ~10 become PIRs; 10-20 continue further investigation at lower priority
• 1-4 PIRs approved for development at final screening stage

• Cross-functional front end teams (2-9 people) remain intact until


products transition into production
• Conducts both initial studies and more rigorous concept evaluations

• Process cycle times:


• Identification: Screening Committee meets every 6-8 weeks
• Concept evaluation: 90-180 days
• New product cycle time: 2-4 years
ESD.61J / 16.852J: Integrating the Lean Enterprise Page 30 © Eric Rebentisch, 2005
Lecture #8: October 05, 2005 Massachusetts Institute of Technology
Source: J. R. Withlin, “Best Practices in User Needs/Requirements Generation”, MS Thesis, MIT 1994
Enterprise Information Systems for PD

• Scope of enterprise-focused PD encompasses


multiple stakeholders, stages of the product
lifecycle
CONCEPT DESIGN MANU-
MANU- PRODUCT RETIREMENT
FACTURING SUPPORT

Customer

Partners

Suppliers

Low Tier Suppliers

Lower Tier Suppliers

Source: Erisa Hines, Lifecycle Perspectives on Product Data Management,

MIT Master’s thesis, August 2005

ESD.61J / 16.852J: Integrating the Lean Enterprise Page 31 © Eric Rebentisch, 2005
Lecture #8: October 05, 2005 Massachusetts Institute of Technology
PDM Systems in Context

• PDM is currently largely focused on engineering


• One part of a larger IT infrastructure
• Many “home grown” applications driven by engineering

• Enterprise IT infrastructure handles broader set of


functions

ERP

MRP

PDM

MANU-
MANU- PRODUCT
CONCEPT DESIGN RETIREMENT
FACTURING SUPPORT

Source: Erisa Hines, Lifecycle Perspectives on Product Data Management,

MIT Master’s thesis, August 2005

ESD.61J / 16.852J: Integrating the Lean Enterprise Page 32 © Eric Rebentisch, 2005
Lecture #8: October 05, 2005 Massachusetts Institute of Technology
Current Issues with PDM Use

• PDM remains focused on the design stage

• Suppliers moving up the food chain: Need for product


data management capability
• Change management and data migration are the biggest
challenges/pitfalls
• Lean principles and practices should be used when
implementing PDM capability
• PDM enables Lean Enterprise Transformation

• opportunity to address enterprise value stream

Source: Erisa Hines, Lifecycle Perspectives on Product Data Management,


MIT Master’s thesis, August 2005

ESD.61J / 16.852J: Integrating the Lean Enterprise Page 33 © Eric Rebentisch, 2005
Lecture #8: October 05, 2005 Massachusetts Institute of Technology
Cross-Platform Commonality Yields Significant

PD Benefits in the Auto Industry

• Result of concurrent technology transfer and multi-project


management
• Data based on 6-year MIT IMVP study of 17 auto manufacturers,
103 new programs

50

40

Percent 30
Reduction
20

10

Eng. Hours Develop. Lead Time No. of


Cost Prototypes
Cusumano and Nobeoka, “Thinking Beyond Lean,” 1998.

ESD.61J / 16.852J: Integrating the Lean Enterprise Page 34 © Eric Rebentisch, 2005
Lecture #8: October 05, 2005 Massachusetts Institute of Technology
Many Opportunities to Benefit from Commonality
in Aerospace Systems Over System Lifecycle

Shared Higher Reduced Greater


Reduced Higher spares complexity
development tooling productivity availability in supply interoperability
costs
Reduced Reduced Reduced Fewer
cycle time spares Higher Reduced maintenance
rework
Design inventory reliability downtime hours
reuse

Rqmts PD Production Operations

Reduced
Process DMS
Lower reuse Reduced
training Reduce Increased
risk Reduced equipment training
testing operator
Reduced Economies time competency
time for Faster of scale
source solutions to Reduced Reduced
selection problems Reduced support
inventory documentation
equipment
ESD.61J / 16.852J: Integrating the Lean Enterprise Page 35 © Eric Rebentisch, 2005
Lecture #8: October 05, 2005 Massachusetts Institute of Technology
Source: Matt Nuffort and Eric Rebentisch, LAI Plenary Conference Presentation, April 2001
Subsystem Commonality Across Product Lines

Reduces Design, Operations & Support Costs

• Commercial Airline:

• Main engine starter is common across 747-400, 767, and


767-300ER
• 26 airports service these aircraft (11 common)
• Airline only has to stock 14 spares, as opposed to 25 if they
were not common

• Military Helicopters:

• 85% commonality between UH-1Y and AH-1Z reduces the


detachment maintenance personnel requirement from
between 4 and 14 people (3 to 12%)

Source: “Managing Subsytems Commonality”, Matt Nuffort and


Eric Rebentisch, LAI Presentation, Apr 10, 2001
ESD.61J / 16.852J: Integrating the Lean Enterprise Page 36 © Eric Rebentisch, 2005
Lecture #8: October 05, 2005 Massachusetts Institute of Technology
Increased PD Performance Using Product

Line Discipline

Organizational Data A B C D
Time Implementing PLE (years) 10+ 4 2a 10
Market Share (%) 75b 94c 60b 55
Overall Size (no. of people)d 5500 2000 1300 5000
Number of Platforms 5 6 1 8
Number of Derivatives 12 9e 0 24
PLE Ratio (Derivatives/Platforms) 2.4 1.5 0 3
PLE Cycle Time Ratio (Derivative Cycle 0.25 0.5 0.35f 0.24
Time/Platform Cycle Time)

• Firms A and D have relatively more mature PLE capabilities


• Long history of using the strategy
• Greater number of derivatives per platform
• Shorter product cycle times through derivatives
Source: Michelle Beckert, Organizational Characteristics for Successful

Product Line Engineering, MIT Master’s thesis, June 2000

ESD.61J / 16.852J: Integrating the Lean Enterprise Page 37 © Eric Rebentisch, 2005
Lecture #8: October 05, 2005 Massachusetts Institute of Technology
Conclusions

• Lean has demonstrated significant product development-


related performance improvements in
• Engineering processes
• Program outcomes
• Company-level performance
• Multi-stakeholder enterprise and system lifecycle
• Basics of value stream mapping, waste elimination, focus on
value, and continuous improvement can be applied in a
straightforward way
• PD increases focus on information management and decision-
making processes across multiple boundaries/stakeholders
• Tools to reduce variation, uncertainty, novelty/exceptions, and
programmatic disruptions (beginning at the front end of PD
through production) enable increased focus on value creation
for customer
ESD.61J / 16.852J: Integrating the Lean Enterprise Page 38 © Eric Rebentisch, 2005
Lecture #8: October 05, 2005 Massachusetts Institute of Technology
Resources

• LAI web site (lean.mit.edu)


• Product lifecycle knowledge area

• Presentations:
• Product Development/Product Lifecycle meetings
• LAI Plenary conference breakouts

ESD.61J / 16.852J: Integrating the Lean Enterprise Page 39 © Eric Rebentisch, 2005
Lecture #8: October 05, 2005 Massachusetts Institute of Technology
Acknowledgements

• Allen Haggerty - MIT, • Earll Murman - MIT

Boeing (ret.)
• Bo Oppenheim - Loyola
• Ronald Bengelink - ASU, Marymount
Boeing (ret.)
• Alexis Stanke - MIT
• John Coyle - Boeing
• Chuck Eastlake - Embry- • Edward Thoms -
Riddle Boeing, IDS

• Dick Lewis - Rolls-Royce • Stan Weiss - Stanford,

(ret.) Lockheed Martin (ret.)

• Jan Martinson - Boeing, • Venkat Allada - U MO

IDS Rolla

• Hugh McManus - Metis


Design
ESD.61J / 16.852J: Integrating the Lean Enterprise Page 40 © Eric Rebentisch, 2005
Lecture #8: October 05, 2005 Massachusetts Institute of Technology

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