The increased international competition in the current open global market is putting pressure on companies to improve the performance of their product development. This is to sustain and improve market share through the production of a high quality product in a cost effective manner in shorter time.

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Manufacturing companies are in need of a new model that goes beyond lean manufacturing to ensure the transformation of the enterprise into lean environment. This is a response to customers and market demands of value creation, incorporating sustainability and customisation. The significant change in enterprise performance can come from the adoption of lean thinking throughout the entire product life cycle, this is the Lean Product Development (LeanPD)

What is needed is a new paradigm that will take the lean manufacturing and lean thinking concepts from waste elimination into value creation. In order to make a significant change in enterprise performance and saving ultimate system costs, there is a need for the entire enterprise to undergo a lean transformation. 

LeanPD focuses on value creation, provision of knowledge environment, continuous improvement and Set-based concurrent engineering process that encourage innovation. It provides process model and associate tools that consider entire product life cycle.


At a glance

  • Dates
    • Please enquire for course dates
  • DurationTwo Days
  • LocationCranfield Campus
  • Cost

    £1,500

    Concessions available

Course structure

Two days • Lectures • Case studies • Hands-on practical exercises

What you will learn

  • Understand key deference between traditional and lean product development
  • Understand and apply lean thinking methodology
  • Evaluate and critically assess current and future level of lean practices in an organisation
  • Improve innovation through implementation of set-based concurrent engineering
  • Understand and apply design for manufacturing and assembly methods
  • Understand and apply A3 thinking for design problem-solving
  • Understand and apply lean knowledge life-cycle approach to systematically capture, re-use and create knowledge in product development
  • Understand and apply trade-off curves to visualise PD knowledge and generate a set of conceptual solutions
  • Introduce LeanPD practices in your organisation

Core content

This course provides the fundamental concepts and working knowledge on Lean Product Development principles, tools, techniques and applications in order to enhance productivity and innovation. The course covers DFMA, SBCE, lean knowledge life cycle, A3 thinking for design problem-solving, trade-off curves and performance measurement. 


Throughout this interactive course you will apply the learning outcomes on real industrial design and product development exercises and learn from the experiences of several industrial case-studies. 

  • Performance measurement– Exercise
  • Concurrent Engineering
  • Introduction to lean product development and its enablers
  • Lean PD performance measurement: Results of the performance measurement exercise
  • Set-based concurrent engineering
  • Set-based concurrent engineering – Exercise
  • Lean knowledge life-cycle (LeanKLC)
  • Introduction to A3 thinking for design problem-solving
  • A3 thinking for design problem solving – Exercise
  • Introduction to Trade-off curves (ToC) to enable SBCE
  • Trade-off curves to support SBCE - Exercise
  • Opportunities for implementation of LeanPD/SBCE

Timetable

Day One

09:00 – 09:30

Performance measurement– Exercise

Aim: To mimic the assessment of the current and desired level of employment of lean practices in the observed organisation, before actually implementing lean thinking in product development. The results will be analysed and discussed during the course.

09:30– 11:00

Concurrent Engineering

Aim: To introduce the concept of concurrent engineering as a multi-disciplinary approach of simultaneous product and process design. It also covers the multi-disciplinary team formation, the PD tools and methods Quality Function Deployment (QFD), Design for Manufacturing and Assembly (DFMA). The participants will perform DFMA exercises using real engineering examples.

11:00 – 11:20

Break

11:20 – 12:00

Introduction to lean product development and its enablers

Aim: Lean product development is an approach originating from Toyota’s Product Development System (TPDS) where focus is shifted from waste elimination to value creation. This session aims to introduce the foundations of Lean PD and its core enablers LeanPD performance measurement, set-based concurrent engineering, Lean Knowledge Life Cycle, A3 Thinking and Trade-Off Curves. 

12:00– 12:30

Lean PD performance measurement: Results of the performance measurement exercise

Aim: To present a method and tool to measure the lean journey within an organisation.  This is to help organisations identify their readiness level for Lean Thinking applications in product design and development In addition, the results of the assessment will be presented and analysed.

12:30 – 13:30

Lunch Break

13:30 – 15:00

Set-based concurrent engineering

Aim: Set-Based Concurrent Engineering is lean thinking methodology that enhances PD performance and increases its productivity and innovation. This session aims to introduce the principles and key activities of SBCE process model. In addition, different tools and methods to support SBCE will be presented and demonstrated through a detailed case study from aerospace.

15:00 – 15:15

Break

15:15– 17:00

Set-based concurrent engineering – Exercise

Aim: To have hands-on experiences and a flavour of the application of SBCE through interactively exercise of developing an office chair

17:00

End


Day Two

09:00 – 09:45

Lean knowledge life-cycle (LeanKLC)

Aim: This session is to present the LeanKLC which is a methodology which enables companies to systematically capture, re-use and create Knowledge in product development.

09:45 – 11:00

Introduction to A3 thinking for design problem-solving

Aim: To introduce the A3 thinking methodology for product design problem-solving based on the learning cycle of PDCA and LAMDA.  Several industrial cases from will be discussed to demonstrate the power of the knowledge capture and visualisation in simple manner.

11:00 – 11:20

Break

11:20 – 12:30

A3 thinking for design problem solving – Exercise

Aim: To have hands-on experiences of the application of A3LAMDA in solving automotive design problem and creating knowledge-based environment. 

12:30 – 13:30

Lunch Break

13:30 – 14:15

Introduction to Trade-off curves (ToC) to enable SBCE

Aim: The session is to introduce ToC as a knowledge visualisation tool which enable SBCE applications through generating sets of designs, comparing different design solutions, narrowing sets of design solutions, and optimising final design solution.

14:15 – 16:00

Trade-off curves to support SBCE - Exercise

Aim: To have hands-on experiences of the application of ToC using realistic industrial data to generate a set of design with SBCE environment.  

16:00– 16:45

Opportunities for implementation of LeanPD/SBCE

The course will close with a brief debate about how LeanPD/SBCE could be introduced and implemented in your organisations and what challenges you may face.

16:45

End of the course


Who should attend

Product development and design professionals, product designers and engineers, continuous improvement managers, lean agents, business managers and project managers.

Concessions

Cranfield alumni will receive a discount of 20%.

Where three delegates or more are booking from within one site or one organisation, a discount of 10% will apply to the invoice for the course tuition fee. Accommodation fees are not included in the discount scheme. Please ask about our discount scheme at time of booking.




Accommodation options and prices

This course is non-residential. If you would like to book accommodation on campus, please contact Mitchell Hall or Cranfield Management Development Centre directly. Further information about our on campus accommodation can be found here. Alternatively you may wish to make your own arrangements at a nearby hotel.

Location and travel

Cranfield University is situated in Bedfordshire close to the border with Buckinghamshire. The University is located almost midway between the towns of Bedford and Milton Keynes and is conveniently situated between junctions 13 and 14 of the M1.

London Luton, Stansted and Heathrow airports are 30, 90 and 90 minutes respectively by car, offering superb connections to and from just about anywhere in the world. 

For further location and travel details

Location address

The course will take place at the Operations Excellence Institute, Building 30 at Cranfield University.

Cranfield University
College Road
Cranfield
Bedford
MK43 0AL

Read our Professional development (CPD) booking conditions.