Design for Lean Manufacturing

Course Description
This new course will show Lean implementers, Champions, and leaders how to (a) provide guidance on how design teams can actually design Lean products for Lean manufacturing (b) help assure the most effective Lean manufacturing results, and (c) help design teams implement DFM and Concurrent  Engineering with so much product development efficiency that Lean resources will still have enough bandwidth to fully  implement the best Lean manufacturing programs.

Design for Lean Manufacturing enables a business model that offers an unbeatable combination of responsiveness, very low cost, and products that customers want when they want them.

Who Should Attend
This course is appropriate for Lean implementers/Champions, Manufacturing Engineers,  design team members, and related managers in the electronics, processing/test/lab equipment, medical products, industrial machinery, power/energy, and aerospace industries. Training is particularly valuable when for products, projects, and markets that have: product variety challenges; unreliable forecasts; inventory problems; or response time opportunities.

Learning Objectives
After learning how to design products for Lean manufacturing, participants will be able to help multi-functional teams concurrently engineer processes to accomplish all of the following:

  • Utilize Spontaneous Supply techniques to “pull in” and deliver readily available parts from the “dock” directly to all points of use, with quality assured “at the source.” This avoids the need for MRP-based  purchase orders, waiting, incoming inspections, and kitting into batches.
  • Offer your most valuable variety as product families (including worthy  legacy parts) on-demand. 
  • Using these principles, build your Lean program without setup delays, batches, or inventory carrying costs.
  • Learn the just-published “Half-Cost-Products” design techniques to cut nine overhead cost categories from half the cost to 1/10.
  • Incorporate into Lean programs the most effective ways to standardize parts to (a) support the most effective Lean initiatives, including the above, (b) cut material overhead to only one tenth on standard parts, and (c) apply many of these overhead cost reductions directly to the selling price without having to change your costing system. 
  • Stop part proliferation right away simply by listing all part categories so that designers can quickly find existing parts instead of adding new, unproven ones.

Course Outline

Design for Manufacturability

  • DFM Guidelines for Assembly and Parts
  • Do it Right the First Time and elimination of change orders

Design for Quality 

  • Prioritize quality improvement opportunity visually
  • Quantify the “cost of quality”
  • Cumulative exponential effect of part quality & count on product quality
  • Mistake-proofing by Design (Poka-yoke)
  • Importance of Design for Lean for product development

Note that the first afternoon session on DFM and quality guidelines has many illustrated examples with 261 slides collected from decades of experience practicing and teaching DFM and Build-to-Order. 

Design for Lean

  • Design for Lean is an with evolutionary self-supporting step that will revolutionize your business model
  • Standardization to enable the best Design for Lean and Lean implementations
  • Concurrently Engineering Lean processing equipment
  • Why offshoring hinders C.E. and Lean Manufacturing
  • Vendor/Partnerships which are pre-selected to be an early and active member of multi-functional design teams
  • Why bidding is counter to vendor/partner teamwork
  • Off-the-Shelf Parts to focus resources on Design for Lean and Implementing Lean

Design for Scalability

  • Importance to  Scalability of DFM and Design for Lean

Concurrent Engineering

  • How C.E. cuts resource demands in half which will enable Design for Lean and better Lean implementations, all of which will cut in half the time to stable production
  • How C.E. efficiencies will give more bandwidth to Lean implementation 
  • Low-Volume/High-Mix environments
  • Designing families and building them on-demand for the best order-fulfillment in your market

Designing Low-cost Products

  • Learn what you can contribute up-front when 80% of cost is determined
  • Most of Womack & Jones “Lean Thinking” cost benefits will be enhanced by this course
  • How to cut nine overhead categories by up to ten times
  • Why “cost reduction” after design can thwart much of this and much of Lean manufacture progress

Course Format
16 hours, presented in four 4-hour virtual sessions
Training will be held in the afternoons of participants’ time zones, from Monday through Thursday, so there is a half-day in between sessions
Each participant will receive a signed 600 page copy of presenter Dr. David Anderson’s book Design for Manufacturability: How to Use Concurrent Engineering to Rapidly Develop Low-Cost, High-Quality Products for Lean Production, 2nd Edition, which can be shown around the company to help spread the word.

April course: 1:00pm-5:00pm (EST) each day
September course: 1:00pm-5:00pm (EST) each day


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