Figure 2: Roadmap of Lean Product Design (LPD)
Formation of
GVE Council
-Dismantle parts
-Grouping / Organize into sub-assembly
-Display / Visual Management
Step 1
Product Tear Down
-First Who…..then What
-Concurrent team approach
-Engineering, Production, Quality Control,
Purchasing, Sale, Maintenance,
Product Design
-Component cost analysis
-Sorting using Pareto Chart
-Identify Vital Component for improvement
Step 2
Prioritization
Step 3
-VOP : Verb-Noun function expression
-VOC : Adverb-Adjective function expression
Function Analysis
-Compare with competitors
-Idea generation using
4 guiding questions
Q1: weight reduce
Q2: geometry reduce
Q3: alternative cheaper material
Q4: lesser scrap residual
-Refine idea and select design
-Change and develop design
-Potential risk analysis – FMEA
-Pilot test / Prototyping
-Quality evaluation (internal / external)
-Customer approval
Step 4
Comparative Analysis
Step 6
Validation
Step 5
Creation
NG
risk of component and product failure but
also any risks to the manufacturing process
and production line. FMEA can eliminate
excessive physical testing, hence reducing
unnecessary cost and speeding up product
development;
ii. Conduct pilot production using sample new
design components to build a prototype to
verify actual performance against design
performance; and
iii. Draft and finalize the specifications needed
to govern the “effective” usage of new design
components in the process and production
lines. The main specifications are:
●●
A standard working manual to guide
operators in handling the product,
●●
Pro c e s s and machine s e t ting
specifications for each work station,
and
●●
Incoming quality control specifications
for newly designed components.
Verifications of real life prototype performance
data from both internal and external sources is
another important task in validation. Essential
internal data is quality reliability, defect rate,
OK
Step 7
Completion
-Follow up
-Financial effect
-Reporting
incoming quality (CpK value) of new components,
process specification and overall machine
efficiency. Important external data is fallout rate
at customer line. The above validation procedures
are illustrated in Figure 1.
Step 7 – Completion
This is the final phase of the lean product design.
Two major tasks are required namely follow-up and
reporting. Main follow-up areas include:
i. Consistency of suppliers in producing new
components that comply with the new
design specifications;
ii Adaptability and suitability of components
used in the work stations producing
finished products; and
iii. Final product quality performance at the
customer side.
The completion of the project needs to be
documented and reported to the management.
The contents of the report include design changes,
ap