Engineering tools for Lean Product Development Process

[mloew]

This could be an interesting new forum. I am currently researching the Toyota Product Development System and how engineering tools (primarily modeling and simulation) can be used to support its implementation. I'm interested to hear how others are implementing a LPDS and what engineering tools they are using.

The book "The Toyota Product Development System" by James Morgan and Jeffery Liker clearly makes the point that engineering tools do not define the process and must be used to fit into the system -- not the other way around. The book cites parametric CAD (notably CATIA in the book because of the focus on body engineering, but Toyota also used Pro/ENGINEER for powertrain) and FEA, but only sparingly. There is little (or no) mention of what systems are used for managing requirements, organizing the design concepts for a "set-based" approach. Not all organizations can simply change their culture to establish the pull-based engineering process that Toyota has and will need to rely on an system to assist with implementing these concepts.

I am currently working on software applications that help engineering workgroups implement these principles. I'm looking for insight into how others are doing this and what the challenges and opportunities they face.

Best regards,

Matthew Ian Loew

http://www.cometsolutions.com

 

[MadMango]

Engineering is only a 1/4 of the whole PDS, the other departments are Marketing, Operations, and Business Unit/Finance. These are used in a 6-stage Phase Gate system.

1 Concept
2 Definition
3 Design
4 Development
5 Pre-Production
6 Production

A project is reviewed at each Phase Gate, and every department has their specific tasks to accomplish. Each Phase Gate is a Go/No Go, where a project is either reviewed and approved, or it is recycled or rejected, even up to the 5th Phase Gate.

"Art without engineering is dreaming; Engineering without art is calculating."

Have you read faq731-376 to make the best use of Eng-Tips Forums?

 

[DKirkham]

Matthew,

We are VERY involved with the Toyota Production System in our shop. I have read many, many, many books on the subject. Because if Shingo and his concept of SMED (single minute exchange of dies), in one instance I cut set up times on our CNC's from 1320 minutes for 88 parts to 14 minutes for 88 parts. Shingo was a genius.

As for software, modeling and simulation there is one thing that I can tell you with certainty...NOTHING will work unless the boss is behind you and relentlessly PUSHES it from the top down.

Eliminating muda (waste) is a never ending task that MOST people are unable or unwilling to understand. Implementing the system is the hardest, and most rewarding, thing you will ever do. I am happy to answer any question you may have regarding our experiences.

 

[toffeet]

Hello Matthew,

This is a very interesting topic and deserves alot more attention. I am also currently busy with the same book.

On what software applications are you currently working on?

Kind regards,
Theodore

Solid Edge V19 SP1 on WinXP SP2

 

[Gensi7]

FAO DKIrkham,

That is a fantastic achievement and as a Production Manager I fully understand and appreciate it. However it did remind me of an article I read when researching Lean. The author was recalling a meeting with the man himself (Dr. Shingo) and as he told him of a similarly excellent reduction of setup time, in this case from 90 mins to 15, Shingo said: "When I was going to school FIFTEEN (15) was still a two-digit number. You must do better!"

A little aside but relevant nonetheless.

Gensi7

 

[mloew]

Theodore,

Thank you for your interest. I am working with several companies to help them develop a simulation-leading product development process that connects the product (and project) requirements and the design and simulation tools. We are able to create processes (Simulation Templates) in such a way that they do not become dependent on the underlying models (CAD or simulation) and therefore can be developed before there are any CAD models and support different design concepts (or sets in LPDP speak).

I don't intend for this thread to become an advertisement for our product and solutions, so if there is specific interest in how we can help you please contact me through our website (

http://www.cometsolutions.com).

I'll be happy to see if I can help you.

Best regards,

Matthew Ian Loew

http://www.cometsolutions.com