The Lean Design Guidebook describes eighteen powerful and practical tools for product development teams that enable dramatic manufacturing cost reduction. The emphasis is on team activities that can create breakthroughs in material, labor, and overhead cost, while maintaining the highest quality and value for customers. An integrated approach to the application of these waste-eliminating tools is described, along with proven methods for training and deployment within a single team, or an entire organization. This is a highly readable book for practitioners in all fields related to product design and development, including design team members, team leaders, managers, and organizational improvement champions. The book makes extensive use of graphics (over 150 figures and diagrams) and is rich with real-world examples and step-by-step descriptions. A bibliography, a comprehensive glossary, and an index are provided.
Acknowledgments
Introduction - About this Guidebooks
Part I : The Business of Lean Design
Section 1.1 : Ground Rules and Basic Tools
Section 1.2 : What's "Lean" Mean?
Section 1.3 : When is a Product Profitable?
Section 1.4 : Screening for Profitable Projects
Section 1.5 : Defining a Target Cost
Section 1.6 : Twenty Levers for Product Cost
Part II : Consider Cost From the Very Beginning
Section 2.1 : Capturing the Voice of the Customer
Section 2.2 : Prioritizing Customer Requirements
Part III : Reduce Cost Through Cross-Product Synergy
Section 3.1 : The Product Line as a "System"
Section 3.2 : Platforms Come in All Sizes
Section 3.3 : Modular, Scalable, and Mass Customizable
Part IV : Cost Leverage is Greatest During Conceptual Design
Section 4.1 : Value Engineering and Analysis
Section 4.2 : The Quick-Look Value Engineering Event
Section 4.3 : Sponsoring a Design Challenge
Part V : Preparing for Production : The "3P" Process
Section 5.1 : What's a Lean Factory Look Like?
Section 5.2 : Overview of Toyota's 3P Process
Section 5.3 : The "How's it Built?" Review
Section 5.4 : The "Seven-Alternatives" Process
Part VI : Attack Direct Costs During Detailed Design
Section 6.1 : What's a Process Capability?
Section 6.2 : Six-Sigma / Robust Design
Section 6.3 : Design for Manufacture and Assembly (DFMA)
Section 6.4 : Achieving Continuous Cost Improvement
Conclusion : A Word About Lean and Green
Glossary
Bibliography
Index
