An opportunity to appreciate the techniques used in Design for Manufacture (DFM) using the Lean principals from Toyota Production System.

At a glance

  • Dates
    • Please enquire for course dates
  • Duration6 weeks
  • LocationOnline
  • Cost£1,500. Concessions available

Course structure

This is an online course with case studies and mentoring bespoke to your business for individual study to develop problem-solving skills and to embed the learning. There is online tuition and mentoring from industry experts and facilitation from Cranfield as well as bespoke assignments for each module. In weeks one to five you will typically spend three hours in online study and up to four hours on assignments and mentoring sessions. In week six your time is dedicated to your final project and review with your mentor.

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

Module 1 - Fundamentals of Product Development and Concurrent Engineering

  • To present different approaches in product development and some of the most common challenges faced in this stage of product life-cycle.
  • 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.

Module 2 – Traditional Product Development Tools and Methods: QFD, DFM, DFA, FMEA, Pugh Matrix

  • To present a view of the interrelations among the different traditional PD tools and methods such as Quality Function Deployment (QFD), Failure Mode and Effects Analysis (FMEA), Design for Manufacturing and Assembly (DFMA) as well as Pugh Matrix.
  • To describe the Design for Manufacturing (DFM) method and its role in ensuring the manufacturability of the component in shorter time and lower cost.  It covers DFx where x is one of the different manufacturing processes such as injection moulding, casting, machining, welding, stamping, etc. The participants will perform DFM exercises using real engineering examples.
  • To describe the Design for Assembly (DFA) principles and method.  In addition its role in designing a product with less components and ensuring manufacturability and assembly in shorter time and leas cost.  The participants will perform DFA exercises using real engineering examples.

Module 3 – Fundamental of Lean Product Development and Set-Based Concurrent Engineering (SBCE)

  • 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. 
  • 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 two detailed case studies from aerospace and security industry.

Module 4 - Lean Knowledge Life Cycle and A3 Thinking for Design Problem-Solving

  • 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.
  • 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.

Module 5 – Trade-off Curves to enable SBCE

  • 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.

Module 6 – Group Project: SBCE Application of Developing an Office Chair

  • To work in a group and to have hands-on experiences and a flavour of the application of SBCE through interactively exercise of developing an office chair

Timetable

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.

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.

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. 

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.

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.

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

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.

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.

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. 

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.

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.  

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.

Who should attend

The course is designed for professionals, career changers, and ambitious, internationally focused graduates looking to enhance their careers in a global context. The target roles include: product development, design professionals, continuous improvement managers, business manager and project managers.

Concessions

10% discount for 3 people or more at the same billing address

10% discount for alumni

How to apply

Read our Professional development (CPD) booking conditions.