Lean Team Takes on Asia -and Wins! December 1, 2009
Posted by Jeff Fuchs in Lean Thinking, manufacturing, product development, supply chain.Tags: Lean Thinking, manufacturing, product development, supply chain
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Who says American manufacturing and lean teams can’t compete with Asia? Not Mity-Lite, which produces chairs and tables for public gatherings. They recently created a mesh chair that is wider, 20% lighter, and durable enough to bear a 1,000 pound load. The seat – dubbed “Mesh One” – looked as though it would have to be produced offshore in order to meet target costs. But an American continuous improvement team stepped in and made a bid for the project.
To win the project from the Asian teams, the American team had to evaluate costs, upgrade facilities, look at things like lead time, cycle time, carrying inventory, and even communications issues. So far, excepting labor, production is on target. CEO Randy Hales has noted that the lean success used for the Mesh One is spreading throughout the rest of the company. But the lean success took the commitment of senior management, and their willingness to shoulder the burden of upgrades and continual improvement. And Mity-Lite is still improving.
Check out the post at the Lean Reflections blog here.
Ford Uses “Skunk Works” to Develop New Engine November 18, 2009
Posted by Jeff Fuchs in automotive, product development.Tags: automotive, product development
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Like all big companies, Ford has a strict product-development hierarchy. Most times it works well, other times a different approach is required.
A “Skunk Works” is an entirely separate and autonomous development team that can move quickly, unencumbered by the rules and restrictions of a typical, integrated development process.
Recently, Ford used the Skunk Works approach for the creation of the new Scorpion engine. The team went offsite with little contact from higher-ups. A handful of rules and creative freedom allowed the development of the heavy-duty engine in record time.
Read more here.
Dell Factors Product “End-of-Life” Issues into the Design Process October 6, 2009
Posted by Jeff Fuchs in manufacturing, product development.Tags: manufacturing, product development
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One of the most encouraging business trends in recent years has been the increased attention to sustainability and the environmental impact of the entire lifecycle of manufactured products. Check out this brief look into how designers at Dell seek continuous improvement through the hands-on destruction of their own machines.
In considering the impact on future recycling efforts, Dell’s Ken Musgrave observes, “participating in this (disassembly) activity teaches the designer the most when it comes to the actual design process. It becomes a study in how past designers and engineers solved the same problem in different ways, such as all the various ways components are held in place and how that process has evolved over time. Those methods will be the difference between gentle persuasions and brute force to separate the parts. They can also make a significant difference in the time it takes to tear one apart, from being measured in minutes to hours.”
To see the full, illustrated article, follow the link here.
Online Calculater Analyzes Cost Savings of Switching to Renewable Packaging April 5, 2009
Posted by Jeff Fuchs in green business, product development.Tags: green business, product development
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It’s hard to evaluate the benefits of switching from corrugated packaging to reusable packaging, besides the obvious sustainability bonus points. But let’s be real—the bottom line is what really matters to most companies, which is why the Reusable Packaging Association (RPA) has created an online Reusable Packaging Economics Calculator to figure out exactly how much cash you can save by embracing recyclables.
The calculator, developed in cooperation with StopWaste, factors in the cost of corrugated packaging, dwell time (how long containers are left at each stage of the supply chain), annual interest rate, cartons shipped annually, return miles for reusables, and the expected replacement rate.
Read the full article here.
Go to the calculator here.
Innovation Trickles in a New Direction April 5, 2009
Posted by Jeff Fuchs in Creativity & Innovation, product development.Tags: Creativity & Innovation, product development
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This month, General Electric’s health-care division will begin marketing a first-of-its-kind electrocardiograph machine in the U.S. It will retail for 80% less than products with similar capabilities. But what really distinguishes the MAC 800 is its lineage. The machine is basically the same field model that GE Healthcare developed for doctors in India and China in 2008.It exemplifies a way of thinking that may be ideally suited to dealing with the widening recession: creating entry-level goods for emerging markets and then quickly and cheaply repackaging them for sale in rich nations, where customers are increasingly hungry for bargains.
The term for this new approach is “trickle-up innovation”, and it is turning conventional product development on its head.
Read more here.
Just Say No To ‘Innovation’ April 5, 2009
Posted by Jeff Fuchs in Creativity & Innovation, product development.Tags: Creativity & Innovation, product development
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While innovation talks about metrics and tangible features, design is usually defined by intuition and intangibles. It is far easier to explain metrics and tangibles than it is “look and feel.” It is also assumed to be safer to make decisions based on numbers and engineering calculations.Yet the core question about design is not “is it a ‘good’ design?”; it’s the other question: “is it the ‘right’ design?”
Read more about how the term “innovation” has been misunderstood and what it means for your products here.
MIT Lean Product Development Survey March 2, 2009
Posted by Jeff Fuchs in Poll/Survey, product development.Tags: product development, survey
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An international research study, “Efficient Introduction of Lean in Product Development,” is being conducted. The study is part of a collaboration between the Lean Advancement Initiative (LAI) of the Massachusetts Institute of Technology (MIT) and the Institute for Manufacturing and Operations Research (IFU) of the Technical University of Braunschweig.
From the website:
The goal of the survey is to investigate how lean principles can be implemented in product development systems to maximize the probability of implementation success and develop a lean product innovation process.
Each person participating in the study by 15 March will receive a written report by July 2009 outlining the results and giving insights derived from analysis of the survey data on how to implement lean product development most efficiently.
Completing the online survey will require 20 to 30 minutes. We would appreciate if you could participate in the study or help to distribute this information to other persons in your company working in the field of product development.
Of course, all the information collected in the survey is treated as highly confidential and individual participants will not be identified.
Take the survey here.
Rollin’ With The Changes January 19, 2009
Posted by Jeff Fuchs in product development.Tags: product development
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When you were a kid, did you have a “little red wagon?” I remember coveting my neighbor’s Radio Flyer jealously. Did you know that it was actually invented by an Italian immigrant in 1917? Back in 1917, the design and materials – wood with metal wheels – were simple, high-quality and a reflection of what the consumer wanted. Same was true for my buddy’s ’70’s-era wagon.
Fast forward to the recent Cloud 9 prototype wagon with an iPod connection, padded seats, air-filled tires with ball bearings, a speedometer and lightweight polycarbonate construction. The prototype shows that the same principles still apply. In a market seemingly dominated by products which focus on electronic-based interaction, Radio Flyer has remained relevant and successful by expanding their offerings, evolving to engage families in what they describe as “active play that inspires adventure and imagination.” While the dedication to innovation, quality and meeting consumer demand hasn’t changed, this is still not the Little Red Wagon that you used to know.
Read about how Radio Flyer has managed to stay around while other toy makers have fallen by the wayside.
Read the full article here.
Designing Profitable Products Using QFD and Kano Model December 22, 2008
Posted by Jeff Fuchs in product development, six sigma.Tags: product development, six sigma
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This posting on iSix Sigma details an example of how Quality Function Deployment and the Kano Model can be used together to help design more profitable products. For those who have not used QFD before, this is a pretty decent introduction into the concept and see how it is used in a simple example. This systematic method forces you to quantify customer wants and needs and assess your product’s features against those of competitors.
Read the article here.
Innovation at Whirlpool Uses Technology, Human Touch November 16, 2008
Posted by Jeff Fuchs in Creativity & Innovation, product development.Tags: Creativity & Innovation, product development
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In 2006, when Dana Nickerson arrived at Whirlpool Corporation, the US$18 billion home appliance maker, he found its product development system hampered by an engineering problem that plagues many large corporations: the inability to find comprehensive data on the parts that go into the company’s thousands of products. That deficiency, in turn, affected the company’s ability to develop new products and get them to market quickly. Nickerson, whose job as Whirlpool’s director of global business process management for corporate technology was to rationalize the management of parts data, compares the situation to having a version of Google Earth that zooms down only as far as the country level. “We had no more visibility into our product information than that,” he says. “What we realized was that we couldn’t use what we couldn’t find.”
Most manufacturers have the same problem. Without structured, easily accessible data models that can integrate information from disparate sources, there is no opportunity to reuse parts or to gain insight from design or test data. Those drawbacks can cripple the design process, especially as it becomes more globally distributed and outsourced.
The article, here, describes Whirlpool’s solutions.
U.S. Manufacturers Lag in Time-to-Market November 7, 2008
Posted by Jeff Fuchs in manufacturing.Tags: manufacturing, product development
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IndustryWeek: The United States has some catching up to do when it comes to getting new products to market faster, according to a study released Oct. 28 by the USC Marshall School of Business’ Center for Global Innovation. The study, based on 430 product categories over 50 years in 31 nations, indicates the leading nations for product-introduction times are more creative.
Read more at: http://www.industryweek.com/ReadArticle.aspx?ArticleID=17646