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Project and Process Development

This document provides tips for attending a webinar, including disabling pop-up blockers, adjusting audio volume, viewing slides, and asking questions. It explains that questions can be submitted during the webinar and will be answered at the end, and any unanswered questions will be responded to on the website. The final section introduces the speaker and his background before turning it over for questions.

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mrtgrpcn
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18 views

Project and Process Development

This document provides tips for attending a webinar, including disabling pop-up blockers, adjusting audio volume, viewing slides, and asking questions. It explains that questions can be submitted during the webinar and will be answered at the end, and any unanswered questions will be responded to on the website. The final section introduces the speaker and his background before turning it over for questions.

Uploaded by

mrtgrpcn
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Webinar “Housekeeping” Tips

Disable pop­up blockers

Adjusting your volume:


• Use the slide at the top right of the console
• Adjust within Windows Media Player or RealPlayer
• Adjust the master sound control on your system (in the control
panel)

Viewing slides
• Enlarge
Webinar “Housekeeping” Tips
Asking questions
• Use the “question” box in the lower right corner

• Submit questions as they occur to you by typing in


the box, then click submit

• Questions will be answered during the Q&A


session at the end of the presentation.
Question and Answer
We will do our best to answer as many
questions as possible in the allotted time.

Answers to the questions that we cannot get to


during the webinar will be answered on our
website soon.

We will notify you when they are available.


Today’s Speaker
Durward Sobek
Associate Professor and Graduate Program
Coordinator of Industrial & Management
Engineering
Montana State University
Bozeman, MT
Al Ward’s Ph.D. student
Laid the basic research foundation
Co­formulated many of the initial ideas in the book,
Lean Product and Process Development
Introducing Al Ward
BA in History, U. of Oregon
Captain of the US Army
Ph.D. in Mechanical Engineering, MIT
Professor of Mechanical Engineering, U. of
Michigan
Machine designer
Observer, thinker, philosopher, author
Why publish now?

His insights into the fundamentals


of PD are powerful, and relevant.

Today I’m going to share a few of those insights with you. I


encourage you to get the book, and read it, as I’ll only be able
to give you a few snapshots. You’ll not think about product
development the same ever again!
The Fundamentals
Purpose and aim of PD
Useful Knowledge
Set­Based Concurrent Engineering
Entrepreneurial System Designers
Teams of Responsible Experts
Cadence, Flow and Pull
What does development produce?

Operational Value Streams


Three Core Value Streams

Saleable
RM
Good

Order $$

Idea Hardware
Three Core Value Streams

Saleable
RM
Good

Order $$

Idea Hardware
Allen Ward’s Insight
Development value streams create
Operational value streams!
Allen Ward’s Insight
Development value streams create
Operational value streams!

Product
Features
Allen Ward’s Insight
Development value streams create
Operational value streams!

Customer

Product
Features
Allen Ward’s Insight
Development value streams create
Operational value streams!

Manufacturing Customer

Product
Features
Allen Ward’s Insight
Development value streams create
Operational value streams!

Manufacturing Customer

Product
Suppliers Features
What is a good development
system?

One that consistently produces


profitable value streams.
From where do profits derive?
Value­ Hardware/
Creating Software
Developer
Effort
Profit
From where do profits derive?
Value­ Hardware/
Creating Software
Developer
Effort Innovation
Profit
Integration

Useful
Good
Knowledge
Decisions
“Value added” in product
development is creating useable
knowledge and equipment.
Generate Useful Knowledge

by exploring multiple solutions


simultaneously;

by aggressively learning about the


solutions, and eliminating weak ones;

by converging on a solution only


after it has been proven.
Set­Based Concurrent
Engineering
This:
Set­Based Concurrent
Engineering
This:

Not this:
+ + pick one
+ synthesize analyze
+ + +
+ + +
+ improve
Trade­off Curves
by analyzing and testing to learn
(not simply to validate)

Useful Not Useful

Test 1 P
Test 2 P
Test 3 F
…
Learning

by validating knowledge through


the fundamental learning cycle

Go Look
See Act
Ask
(in) Ask Discuss
Form Why Model
Capture & Reuse the
Knowledge

by synthesizing and documenting

Limit and trade­off curves


Succinct reports
Engineering standards / design guides
Reflection
Is deep technological know­how
enough?

NO!

It must be integrated.
A Story…
Sobek­san, what
do you think of the
new Taurus?
A Story…
Sobek­san, what
do you think of the
new Taurus? ???
A Story…
Sobek­san, what
do you think of the
new Taurus? ???

All the parts on the are


best­in­class…
A Story…
Sobek­san, what
do you think of the
new Taurus? ???

All the parts on the are


best­in­class…

…but it is not a great car.


How do you resolve:
Design balance?
Subsystem design
convergence?
Conflicting
customer desires?
Subsystem interactions
producing desired effects?
How do you resolve:
Design balance?
Subsystem design
convergence?
Conflicting
customer desires?
Subsystem interactions
producing desired effects?

Toyota’s Remedy: The Chief Engineer


The Chief Engineer
Leads vehicle development project…
Designs the system architecture…
Plans the development process… and runs it…
Drives consensus and tradeoffs…
Represents the customer…
Makes money.
But most of the developers do
not report to the Chief
Engineer!

Who does the work?

Teams of responsible experts.


Teams of Responsible Experts
Create new knowledge around a subsystem…
Communicate it…
Represent it to others, esp. the Chief
Engineer…
Focus on overall project success…
Build expert teams by avoiding
handoffs

Knowledge

Responsibility

Feedback Action
Make Growing People a
Priority

Q: What is your most important job as


an engineering manager?
Make Growing People a
Priority

Q: What is your most important job as


an engineering manager?

A: Helping my people
become the best
engineers they can be.
Make Growing People a
Priority

Q: What is your most important job as


an engineering manager?

A: Helping my people
become the best
engineers they can be.

Technical Knowledge & Problem­Solving Skill


“Lots of conflict
makes great cars.”
­ Toyota Chief Engineer
Manage the Flow
by eliminating muri

Lead
Time

0 % Utilization 100
Manage the Flow
by eliminating muri

Lead HOW? Target events that “pull”


Time
developer effort

0 % Utilization 100
Manage the Flow

by eliminating mura

Variability will be buffered by some


combination of inventory, capacity and time.
­ Hopp and Spearman,
Factory Physics
Manage the Flow

by eliminating mura

HOW? Cadence.
Variability will be buffered by some
combination of inventory, capacity and time.
­ Hopp and Spearman,
Factory Physics
Manage the Flow

by eliminating muda
Any activity that does not:
• directly result in hardware/software
• produce useable knowledge

should be eliminated,
or redesigned so that it does.
The Basics
The object of the game is to make profit,
consistently.
The operational value stream generates the
profit.
The rate and quality of output from development
depend critically on knowledge.
The Basics, cont.
Generate knowledge through set­based
concurrent engineering.
Grow teams of experts who can use, generate
useful knowledge.
Establish and support entrepreneurial system
designers.
Eliminate overburden, instability, and waste
through cadence, pull, and flow.
Al’s Hypothesis

Focusing on these fundamentals will


greatly improve product development
performance.

Will you help us test the hypothesis?


"Perfection is not attainable. But if we chase
perfection, we can catch excellence."
­Vince Lombardi
Webinar Attendee Discount!

15% Off
Lean Product and
Process Development
by
Allen C. Ward
Use Discount Code:
WEBINAR
Offer expires 5/3/2007
Cannot be combined
with any other
discounts.
Question and Answer
Use the “question” box
in the lower right corner

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