Kaizen/3P in new product development?

[McLeod]

If any readers have experience with Kaizen and/or Product Preparation Process ("3P&quot programs in new product development projects:

- What did you find to be the advantages and disadvantages of the methodology?

- How would you compare these concepts to other existing development/quality/efficiency initiatives (Concurrent Engineering, Total Quality Management, Six Sigma, Zero Defects)?

- What kind of problems did the methods (a) cause, and (b) solve?

- Did the methods significantly improve the product, process, or project schedule?

- What has to happen in order for the methods to be intelligently applied, so that inherent pitfalls can be avoided?

- Is it just me, or are all of these programs just re-hashing of old methods, cloaked in new buzzwords to make them appear to be the new silver bullet which actually works?

 

[PSE]

It all depends upon the nature of the beast you are contending with. Try to match methods to the type of product you are working with (high volume, custom items etc.) as some "tools/methods/buzzwords" will work better than others.

In general:

1) Communicate! Get everyone involved up to speed as early as possible because the time "remaining" to market gets ever shorter. I suppose this is the Concurrent Engineering as manufacturing can provide feedback to design and QC can work on developing test/measurement equipment. Procurement can line up suppliers. Operators are also important as they may have invaluable insights and can get an early start on training.

2) Identify the performance requirements of what you are producing. This is your goal to work on and will identify the methods needed to reach and measure it. Proactive controls (spc) are better than reactive controls (inspection) but may be harder to implement.

3) If there is measurement equipment involved in the process, make sure that it is capable of measuring the needed characteristic (Gage R&R)

4) Get your product stable before starting continuous improvement methods. Otherwise you may have no idea if you are positively or negatively affecting the process.

5) Maintain a sense of humor. Disasters happen occasionally.

 

[rka77]

The Kaizen is an excellent tool which is mostly based on improvements with out big investment.It focusses on the involvement of the all concern and utilising all energies available to streamline the methodologies and see the synergies. The core of improvement is the observation by individual and see beyond the normal observations made on daily basis. This creates a real improvement by the most concerned person responsible for the area.
It is little different though the objective off all programs is the same. This identifies and removes the error possibilities,
Thanks.
Best Regards
rka77