LeanPD Course

Lean Product Development
short Course​

Lean Product Development – 2 Day Intensive Course

Course Overview

This comprehensive course provides fundamental concepts and practical working knowledge on Lean Product Development principles, tools, techniques, and applications. The program is designed to enhance productivity and foster innovation in product development processes.

Throughout this interactive course, participants will apply key learning outcomes on ‘real’ industrial design and product development exercises, and gain valuable insights from several industrial case studies.

DFMA SBCE A3 Thinking Trade-off Curves Lean Knowledge Cycle

Course Outcomes & Objectives

 

Understand Key Differences

Distinguish between traditional and lean product development approaches

 

Apply Lean Methodology

Understand and apply lean thinking methodology in product development

 

Assess Lean Practices

Evaluate current and future levels of lean practices in organizations

 

Enhance Innovation

Improve innovation through set-based concurrent engineering implementation

 

DFMA Application

Understand and apply design for manufacturing and assembly methods

 

Problem-Solving

Apply A3 thinking for effective design problem-solving

 

Knowledge Management

Implement lean knowledge life-cycle approaches for knowledge capture and reuse

 

Trade-off Analysis

Use trade-off curves to visualize PD knowledge and generate solutions

 

Organizational Implementation

Introduce and implement LeanPD practices within your organization

Course Schedule

Day 1
09:00 – 09:30
PD Performance Measurement – Exercise
Mimic the assessment of current and desired levels of lean practices in an organization before implementing lean thinking in product development. Results will be analysed and discussed during the course.
09:30 – 11:00
Concurrent Engineering
Introduce concurrent engineering as a multi-disciplinary approach of simultaneous product and process design. Covers multi-disciplinary team formation, QFD, FMEA, Pugh Matrix and DFMA. Participants will perform DFMA exercises using real engineering examples.
11:00 – 11:20
Break
11:20 – 12:00
Introduction to Lean Product Development
Originating from Toyota’s Product Development System (TPDS), focusing on value creation rather than waste elimination. Introduces foundations of Lean PD and its core enablers.
12:00 – 12:30
Set-Based Concurrent Engineering 
Lean thinking methodology that enhances PD performance, productivity, and innovation. Introduces principles and key activities of SBCE process model with tools and methods demonstrated through an aerospace case study.
12:30 – 13:30
Lunch Break
13:30 – 15:00
Set-Based Concurrent Engineering – Exercise
Hands-on experience applying SBCE through interactive exercise of developing an office chair.
15:00 – 15:15
Break
15:15 – 17:00
Set-Based Concurrent Engineering – Exercise
Hands-on experience applying SBCE through interactive exercise of developing an office chair.
17:00
End of Day 1
Day 2
09:00 – 09:45
Lean Knowledge Life-Cycle (LeanKLC)
Methodology enabling companies to systematically capture, reuse, and create knowledge in product development.
09:45 – 11:00
Introduction to A3 Thinking for design problem-solving
A3 thinking methodology for product design problem-solving based on PDCA and LAMDA learning cycles. Industrial cases demonstrate knowledge capture and visualization.
11:00 – 11:20
Break
11:20 – 12:30
A3 Thinking – Exercise
Hands-on experience applying A3LAMDA in solving automotive design problems and creating a knowledge-based environment.
12:30 – 13:30
Lunch Break
13:30 – 14:15
Introduction to Trade-off Curves (ToC)
Knowledge visualization tool enabling SBCE applications through generating design sets, comparing solutions, narrowing options, and optimizing final designs.
14:15 – 16:00
Trade-off Curves – Exercise
Hands-on experience applying ToC using realistic industrial data to generate design sets in an SBCE environment.
16:00 – 16:45
Implementation Opportunities
Debate on introducing and implementing LeanPD/SBCE in organizations and potential challenges.
16:45
End of Course

Instructor & Contact

 

Dr. Ahmed Al-Ashaab

Lean Product Development Expert

+44(0)7383 54 8475
ahmed@digitalleanexchange.com
Digital Lean Exchange Ltd, Milton Keynes, UK

 

Course Payment

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