Abstract
Current products in the market are customer oriented. Customers demand for low priced products in minimum possible time of production. To achieve competitiveness and to stay ahead in the business, manufacturers adopt lean manufacturing strategies. Lean principles are focused on elimination of wastes, streamlining the processes there by reducing cost and product delivery time. Lean concepts are widely used in process perspective; there exists scope for applying lean principles for product development. Product development involves various stages associated from collection of customer requirement till the realization of products. In this context, this chapter presents a framework for Lean Product Development using a primary lean tool Value Stream Mapping. The chapter is exemplified with a case study conducted in an Indian automobile component manufacturing organization. The approach starts with the preparation of current state map indicating the details associated with each and every stage of Value Stream Map (VSM ). This is followed by detailed analysis of VSM, followed by the identification of areas where improvements can be brought about. Then Quality Function Deployment (QFD) is integrated into VSM to facilitate design improvements and to achieve customer oriented products; also, elimination and integration of certain processes in process map is done to achieve stream lined process. Finally, Future state Product Development map is developed indicating the improvement proposals and possible time reduction as a result of modifications in the design process. This methodology would facilitate a framework for product development process with the incorporation of lean methodologies.
This is a preview of subscription content, log in via an institution.
Buying options
Tax calculation will be finalised at checkout
Purchases are for personal use only
Learn about institutional subscriptionsReferences
Besterfield D, Besterfield G, Urdhwareshe H, Carol Besterfield S (2003) Total quality management, 3rd edn. Pearson Education Inc., New Delhi
Chen L, Chang W (2009) Fuzzy linear programming models for new product design using QFD with FMEA. Appl Math Model 33:633–647
Fritzell I (2012) Value stream mapping in product development. Master thesis. Chalmers University of Technology, Sweden
Haque B, James-Moore M (2004) Applying lean thinking to new product introduction. J Eng Des 15:1–31
Khan M, Al-Ashaab A, Shehab E, Haque B, Ewers P, Sorli, Sopelana A (2013) Towards lean product and process development. Int J Comput Integr Manuf 26(12):1105–1116
Kreng V, Lee T (2004) QFD-based modular product design with linear integer programming—a case study. J Eng Des 15(3):261–284
Kumar PSS, Balasubramanian S, Suresh RK (2009) Optimization of lean new product development process using advanced dual stage performance phase method. Int J Recent Trends Eng 1(5):71–76
Lindlöf L, Söderberg B, Persson M (2013) Practices supporting knowledge transfer—an analysis of lean product development. Int J Comput Integr Manuf 26(12):1128–1135
Liu H (2009) The extension of fuzzy QFD: from product planning to part deployment. Expert Syst Appl 36:11131–11144
Mcivor R (2001) Lean supply : the design and cost reduction dimensions. Eur J Purchasing Supply Manag 7(4):227–242
Oppenheim BW (2004) Lean product development flow. Syst Eng 7(4):352–376 (Wiley Periodicals, Inc)
Pullan TT, Bhasi M, Madhu G (2013) Decision support tool for lean product and process development. Prod Plann Control 24(6):449–464
Sakao T (2007) A QFD-centred design methodology for environmentally conscious product design. Int J Prod Res 45(18–19):4143–4162
Schulze A, Schmitt P, Heinzen M, Mayrl P, Heller D, Boutellier R (2013) Exploring the 4I framework of organisational learning in product development: value stream mapping as a facilitator. Int J Comput Integr Manufact 26(12):1136–1150
Smith LG (2012) An improved custom development process utilizing lean methods and tools (2012). Masters thesis, paper 32. Grand Valley State University
Walton M (1999) Strategies for lean product development. The Lean Aerospace Initiative, Working Paper Series, WP99-01-91. Massachusetts Institute of Technology, pp 1–91
Zhai L, Khoo L, Zhong Z (2008) A rough set based QFD approach to the management of imprecise design information in product development. Adv Eng Inform 23(2):222–228
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2015 Springer International Publishing Switzerland
About this chapter
Cite this chapter
Vinodh, S., Chethan Kumar, A.G. (2015). A Case Study on Lean Product and Process Development. In: Davim, J. (eds) Research Advances in Industrial Engineering. Management and Industrial Engineering. Springer, Cham. https://doi.org/10.1007/978-3-319-17825-7_2
Download citation
DOI: https://doi.org/10.1007/978-3-319-17825-7_2
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-319-17824-0
Online ISBN: 978-3-319-17825-7
eBook Packages: EngineeringEngineering (R0)