Lean Product Design

3 days

course code 2.7

What is the course for

#1

Reduce the industrial complexity of products

#2

Learn to use standardisation techniques effectively

#3

Acquire the techniques for reducing product cost 

The challenges to be overcome during a product’s life must be confronted during the product design phase. Being able to design a product with improved reproducibility in mind, together with reducing its complexity, becomes a strategic factor in how competitive the product will be. Today, companies are increasingly struggling with mass standardisation and the desire to customise products on an individual basis for each customer. The “mass personalisation” of products is becoming the main feature of the market for many successful companies, by finding the most efficient way to meet the contextual needs of quick response, product flexibility and low cost, as well as sources of innovative modularity.

The two objectives are:

  1. Continuous differentiation of the product/service in line with customer needs
  2. Continuous cost reduction with increased efficiency of production and distribution processes

These goals can be achieved by applying the principles of Lean Product Design which use a variety of techniques to reduce product costs without affecting the overall product quality and its perceived value to the final customer, and by repurposing certain typical mass production requirements and applying them in different ways. Standardisation and economies of scale are mainly applied to the hidden parts of the product, while providing customisation through the external design and other more visible components of the product or service.

Goals

  • Reduce the industrial complexity of products
  • Learn to use standardisation techniques effectively
  • Acquire the techniques for reducing product cost
  • Reduce the complexity of product architectures without affecting the breadth of the range and offering to the market
  • Acquire the techniques to increase productivity
  • Reduce industrialisation times by increasing their effectiveness concerning production issues

Addressed to

  • Manufacturing companies
  • Business unit supervisors
  • Marketing management, product managers
  • Technical directors, R&D managers
  • Industrial management, heads of industrialisation, strategic purchasing managers

Contents

Lean Design

  • Analysing waste inherent in products (functional analysis and tear down)
  • Reducing product costs (tear down, target cost management, should costing)
  • How to lay out a modular design (gamma plan and modular design)
  • Simultaneously designing product and process and the impact of modularity on the process
  • Standardisation
  • Reduce manufacturing costs derived from incorrect planning (design for assembly, design for error proofing)
  • Determine and govern risks linked to incorrect product planning (failure mode and effects analysis)

Modularity and standardisation vs Variety Reduction Program (VRP)®

  • Modular Design methodology vs VRP (Variety Reduction Program)
  • Product architecture and the gamma plan
  • How to lay out a modular design
  • How to simplify product architecture
  • Simultaneously design product and process and the impact of modularity on the process
  • Customise the product at a later date (product variety funnel)
  • Mass customisation

Design for X

  • The impact of design on assembly and the concept of design efficiency
  • The Design For X process
  • How to reduce the number and type of components
  • How to prevent errors in assembly (error proofing and Poka Yoke)
  • Rules to simplify the handling of parts
  • Rules to simplify assembly of the parts
  • Design for manufacturing

You will experience

  • Analysing a product’s value
  • Reduce a product’s cost without affecting quality and value for the customer
  • Simplify the product structure by increasing industrial efficiency
  • Eliminate industrial waste derived from poor product design
  • How to simplify product assembly

Download the in-company training catalogue