lean pd050907

How PLM Technology Catalyzes

Lean Product Development

Global Services Director

PTC Proprietary and Confidential © 2007 PTC

May 2002Toyota selects

Pro/ENGINEER for

Powertrain

October 2003 Toyota and PTC join in

Development effort for

Powertrain

Development System

June 2004

New Strategic PLM and

Process Improvement

Solutions Deployment for

Toyota’s Powertrain marks

Milestone of Multi-year Joint

R&D Agreement Between

PTC and Toyota

PTC Partnership with Toyota Motor Corporation

Celebrated MilestonesJune 2006

Toyota confirms plans for

Web Based Product Data

Management Deployment in

August 2006

2001

Toyota’s first large

implementation of

Pro/ENGINEER

“PTC has been a skilled and experienced partner to us in this major

undertaking to improve our processes throughout the powertrain

division. PTC’s comprehensive Product Development System clearly

aligns with Toyota’s approach to product design and development …”

Mr. Miko Satoh, Toyota’s general manager of Corporate IT

Toyota EngineersPTC HQ in Needham, MAPTC’s Largest Customer (2004 - 2006)


Overview

Framework for Understanding Lean Product Development

… People, Process, Technology

Demystifying Lean Process Initiatives

… in a Global Development context

Role of Technology in enabling Lean Process Initiatives

Customer Scenarios

Next Steps


Pe

op

le

Leadership by ExampleMulti Skilled Technical

Workforce

Personal Responsibility for

Performance

Commitment To Total Customer Value

Lean Product Development Framework

Pro

ce

ss

Te

ch

no

log

y


Pe

op

le


Workforce


Performance


Lean Product Development Framework

Pro

ce

ss

Te

ch

no

log

y

Flowing Processes

Integral Product Development System


Importance of Information Flow to Product Development Processes

Information is created during development, how well it flows is critical

Ideal design creates information with minimum waste

Continuous flow of small batches of information reduces waste

Converting information to reusable knowledge reduces waste

Hoult et al., MIT DoD Program Analysis

“Cost Awareness in Design: The Role of Data Commonality”

Physical Product

Physical Product

ENGINEERING

MANUFACTURING

SUPPLIERS

PROCUREMENT

MARKETING

SALES

SERVICE

CUSTOMERSDigital Product

Digital Product

Digital Product

Digital Product

Release toManufacturing

Digital Product Value Chain


Importance of Technology Infrastructure to Information Flow

Disconnected

Many separate applications and databases

Many manual transfers of information

Little information flow

Procurement Manufacturing

Engineering Partners

Marketing Sales

Integrated (System Integrated)

Brittle connections

Information lost in transfer

A challenge to integrate, maintain, extend

Information flows in bursts or slowlyPoint to Point Hub & Spoke



Marketing Sales



Marketing Sales

Integral System

A single source of truth

High fidelity information flow

Easy to maintain, extend

Information flows rapidly and consistently

PRODUCT DEVELOPMENTSYSTEM



Marketing Sales


Process and Technology in Lean Product Development

Pro

ce

ss

Te

ch

no

log

y

Front Loading

Visual

Planning and

Tracking

Standard

Work

Systematic

Knowledge

Capture and

Reuse

Mfg and

Supplier

Partnering

Efficient

Design

Review

Flowing Processes


Rich Design

Authoring

&

Simulation

Document

Authoring &

Dynamic

Publishing

Manufacturing

Process

Planning

Visualization

&

Mockup

Enterprise

Content &

Process

Management

Distributed

Collaboration

&

Planning

Pe

op

le


Workforce


Performance




Front Loading

Visual Planning and

Tracking

Standard Work

Systematic Knowledge Capture and

Reuse

Mfg and Supplier

Partnering

Efficient Design Review

Lean Process Initiatives

Manufacturing Process Planning

Document Authoring &

Dynamic Publishing

Visualization & Mockup

Enterprise Content & Process

Management

Distributed Collaboration &

Planning

Rich Design Authoring & Simulation

Key S

upport

ing T

echnolo

gy


Some examples of how technology can enable each initiative

Front Loading

Visual Planning and

Tracking

Standard Work


Reuse

Mfg and Supplier

Partnering





Dynamic Publishing



Management


Planning


Key S

upport

ing T

echnolo

gy


FRONT LOADING

Set Based Design

CONCEPTSELECTED

Front Loading

Visual Planning

and Tracking

Standard Work

Systematic Knowledge

Capture And Reuse

Mfg And Supplier

Partnering


Front Loading

Explore the range of possibilities early on, evaluating multiple product

and production process options without committing in advance to any

given alternative. This provides flexibility when encountering problems

and increases the chances of arriving at an optimal solution with safe

performance envelope.

How predictable is your development cycle?

How much unanticipated design rework do you do downstream?

How effectively do you reuse existing designs?

How many candidate designs do you explore? Does your process support this?

How well is your product architected to evaluate multiple alternatives?


FRONT LOADING

Set Based Design

CONCEPTSELECTED

Example …


Distributed Collaboration & Planning


Management

Visualization& Mockup


Dynamic Publishing



VISUAL PLANNING & TRACKING

Provide transparency for all into current key project activities and design

performance indicators, making it easier to work in smaller batches of

intellectual property. This facilitates smoother product development flow

than typically found in large-batch stage/gate project execution.

How easy is it for distributed stakeholders to access rich current project information?

How do you determine whether a distributed project is on schedule?

How much time and money are invested before key issues surface?

How are participants notified of changes that affect their work?

Front Loading

Visual Planning

And Tracking

Standard Work


Capture And Reuse

Mfg And Supplier

Partnering


Visual Planning and Execution



Management


Rich Design Authorign & Simulation

Expose live critical project and product KPIs to geographically distributed teams

VISUAL PLANNING & TRACKING

Example …



Dynamic Publishing



STANDARD WORK

Step 1

---------------------------

Link to Best Practices

Step 2:

---------------------------

Link to Template

---------------------------

Step 3:

---------------------------

---------------------------

Link to Library

Front Loading

Visual Planning

and Tracking

Standard Work


Capture And Reuse

Mfg And Supplier

Partnering


Standard Work

Develop and continually evolve best practices for work activities, based on

practical experience. Standard work definitions improve task efficiency

through increased predictability and reliability, and also provide the basis

for continually identifying and institutionalizing improvements.

How consistently is work carried out by knowledge workers?

Is it difficult to balance workload because key knowledge resides in the heads of a few?

How do you ensure that knowledge does not leave with retirees or contractors?

How do your knowledge workers identify and institutionalize improvements to work methods?

How easy is it for a global team to access up to date standard work definitions?


STANDARD WORK

Standard Engineering Calculations

Standard Change Process

Standard Simulation Methodology

Examples …


Management


Management





Dynamic Publishing




SYSTEMATIC KNOWLEDGE

CAPTURE & REUSE

Examples of Knowledge Capture

Front Loading

Visual Planning

and Tracking

Standard Work


Capture And Reuse

Mfg And Supplier

Partnering



Reuse

Solve problems at their root and add to the stock of knowledge. This

reduces the number of problems to address and allows you to reuse

knowledge from past learning in future work to improve products and

processes.

How frequently do you find yourself “solving” the same problem more than once?

How are insights gained from one project applied to other projects?

How well do you reuse design lessons-learned?

How do you capture and share product and process knowledge across a distributed organization?

How many places do you have to look to find what you need?

Is cross-discipline knowledge in multiple places?

When do you provide access to knowledge (push / pull)?

PROJECT PLANS

PROCESS WORKFLOWS

PROBLEM SOLVING

DOCUMENTS

ENGINEERING CALCULATIONS

CAD PART

TEMPLATES

CLASSIFIED PARTS and FEATURE

LIBRARIES

TECHNICAL DOCUMENTS


SYSTEMATIC KNOWLEDGE

CAPTURE & REUSE

Typical Detailed Design processDesign in validated manufacturing strategies

4. Release

2. Creation

1. Planning

Analyze Inputs

Incorporate Intent & Req

Insource/ Outsource

RequirementsPartial Physical ArchitectureDesign InterfacesConcept Design

Requirements ManagementConcept Development

System Design

Complete Inputs

Complete?

Create Design

Evaluate and Learn

Approve?

3. Documentation

Complete Deliverables

Review for Release

Approve?Final DesignDesign Documentation

Verification & Validation

Outsourced Design

Manufacturing Planning

Manufacturing Planning

Example …





Management




Dynamic Publishing


Key to front loading product development is involving all those with a stake

in successful volume production of product. Team members who are

responsible for downstream execution provide critical insight that should

be included early in the design to minimize costly surprises later.

MANUFACTURING & SUPPLIER

PARTNERING

How early is manufacturing involved in product development?

How well is manufacturability addressed in your current design process?

How early do you consult with your suppliers during design?

How much do you benefit from the experience of your suppliers during design?

Is your product well architected for distributed development?

Front Loading

Visual Planning

and Tracking

Standard Work


Capture And Reuse

Mfg And Supplier

Partnering


Manufacturing and Supplier Partnering


MANUFACTURING & SUPPLIER

PARTNERING

CAD ModelData Sheet

Requirements

Viewable

Software Code

Manufacturing Collaboration

Evaluate ‘Manufacturability’

Manufacturing

Test Plan

Analysis

Marketing

Sales

Engineering

Supplier Collaboration

Investigate New Component

Engineering

Finance

Procurement

ManufacturingSales

Marketing

Supplier BAsia

Supplier AEurope

Supplier CNorth America

Design Partner

Team Coordination

Complex Engineering Change

Engineering Europe Supplier

Design Partner ManufacturingProgramManager

EngineeringNorth America

Example …

Global Collaboration





Management



Dynamic Publishing



EFFICIENT DESIGN REVIEWFront

Loading

Visual Planning

And Tracking

Standard Work


Capture And Reuse

Mfg And Supplier

Partnering



By continuously resolving issues as they arise, design review focuses on

convergence of design rather than solving large batches of accumulated

design problems. The result is more efficient decision-making with

continuous momentum towards a coherent total design that will best fit

customers’ needs.

How many problems are discovered or missed during formal design review?

How much valuable design time is spent preparing for design reviews?

Do you compromise on reviews because they are difficult to prepare for?

Is live design data available to the distributed team all for frequent virtual review?

How easy is cross-discipline communication?

Do fixes to a problem cause regressions elsewhere?

Problems

Open

Batch

resolution

Continual

resolution


Examples …

EFFICIENT DESIGN REVIEW

Global collaboration

tools

Design review preparation

and executionGlobal access to

latest data



Management





Management



Dynamic Publishing




Front Loading

Visual Planning and

Tracking

Standard Work


Reuse

Mfg and Supplier

Partnering





Dynamic Publishing



Management


Planning


Key S

upport

ing T

echnolo

gy


Overview of Key Supporting Technology

Engineering calculations

MCAD/CAM/CAE …

Rich Design

Authoring

&

Simulation

Enterprise

Content &

Process

Management

Distributed

Collaboration

&

Planning

Data sharing

Collaboration tools

Project management

Reporting …

MCAD/ECAD/Software/ Document management

Lifecycle management

Workflow

Change processing …


Visualization

&

Mockup

Manufacturing

Process

Planning

Document

Authoring &

Dynamic

Publishing

Overview of Key Supporting Technology (cont)

XML authoring

Technical illustrations

Dynamic document assembly

Multi-format publishing …

Manufacturing process definition

Manufacturing resource management

Document visualization

Mechanical and electrical visualization and verification

Digital Mockup …

Customer Scenarios


Toyota Motor CorporationTechnical Focus Areas for Improvement

Integrated Quick CAE

Full 3D annotation to remove drawings from critical path

Integrated and associative NC planning and machining

Improved internal and supply chain collaboration & mobility

Managed storage and reuse of existing knowledge

Web-based database centralizing and controlling design data and processes

Driven by Process Improvement Goals and Studies …

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Goal

Increase Innovation Flow

Decrease Time To Market

Lean out Product Development Process

Update Technology

Gains: 2000 - 2006

CAD Efficiency – Increased 2000%

Overall Engineering Efficiency – 4X

Time to Market – Reduced 62%

Product Introductions – Up 367%

PINGNew Product Introductions Quintupled and Time to Market Reduced

Solution

Used PTC software to expand product development capacity, explore simultaneous new designs, and refine engineering strategies. Also developed an action plan for a lean enterprise.

Next Steps


Optimizing Your Product Development Processes

PTC Mission

Help our customers improve their product development processes

Keys to Customer Success


Focus on Realized Value outcome

PLAN VALUE BUILD VALUE REALIZE VALUE


The PTC Value Roadmap

Strategy Initiatives Operations Capabilities

Product

Development

strategies that

enhance

business value.

Actions taken to

create value

through changes in

people, process or

technology.

Processes

throughout the

digital product

value chain

where initiatives

are implemented.

A product

development

system that must

be in place for an

initiative to be

successful.

Value

Opportunities

Business

InitiativesProcesses Capabilities

Ensure Strategies are SuccessfulStrategize

Tie Processes and Initiatives to Corporate Objectives

Align

Configurable knowledge base for use with PTC Customers

Supports a guided discussion

Value Identification


What you can do today …

Learn more at PTC resource websites for

Global and Lean Product Development

Explore process improvement

opportunities within your organization

Schedule working session to review the PTC

Value Roadmap

Take advantage of PTC Global Services

expertise to take your next steps in Global

and Lean Product Development

lean pd050907

Documents

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importance of information

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