Lean Product Development

Despite an increasing need for speed and efficiency, much of the effort expended by product development teams is often unnecessary and potentially wasteful. In many cases, only one or two hours of a team member's work day is actually spent directly creating value for their customers. The Lean Product Development workshop presents a set of leading-edge, practical tools for slashing waste and increasing speed and efficiency for any product development process. The twenty-eight "lean techniques" described in this course enable dramatic reductions in time-to-market while freeing up valuable resources for additional development work. Firms that have embraced these practical, waste-eliminating tools have reported up to 50 percent reduction in launch schedules, dramatic improvements in gross margin, and enhanced customer satisfaction. This hands-on workshop covers all aspects of the subject, including a step-by-step approach for creating your own lean process that will enable rapid, high-value product development.

Class Details

Class Name:
Lean Product Development
Product-line managers, team leaders, task managers, functional managers, six-sigma blackbelts / green belts, improvement champions, operations managers, process owners, design engineers, and all others with product development responsibilities.
2 Day Course

Learning Objectives

  • Identify non-value-added tasks and wasteful work habits on any development project.
  • Apply twenty-eight lean techniques that provide immediate savings of time and cost.
  • Use a step-by-step method for prioritizing improvement activities.
  • Improve the quality and efficiency of customer / team / management communication.
  • Maximize utilization of scarce human and capital resources.
  • Support a culture of discipline, value-focus, and intolerance of waste.

Outline At-a-Glance

How You Will Benefit

  • Typical sources of waste in product development
  • A common-sense, toolbox approach

A Brief "Lean Thinking" Tutorial

  • How the five principles of lean thinking apply to new product development
  • Avoiding undershoot and overshoot of customer needs
  • Exception management, and other fundamental concepts
  • The "Continuous Flow" development process

A Toolbox for Speed and Efficiency

  • Testing for Customer Value
  • Linked Tasks and the Deliverables Roadmap
  • Time Slicing and Stand-up Meetings
  • Project Data Management
  • The "Waste-Free" Design Review
  • Staged-Freeze Specifications
  • Value Stream Mapping for Waste Elimination
  • Standard Work Methods and Templates
  • Risk Buffering and Value Increments
  • Resource Prioritization and "Superteams"
  • Lean Supplier Management
  • Lean Self-Assessment and Kaizen Tools

Job Roles