An exploration of knowledge and understanding – the eighth flow

The argument for understanding Lean construction as a socio-technical field is growing and the need to better consider the role of human beings within construction systems is becoming the dominant factor in project success. Many current attributes of lean already focus on people and on human engagement approaches but the field of lean construction addresses project environments that are often complex and highly variable. The authors argue that the successful delivery of these projects relies on the creation of a common understanding of the project objectives within the diverse value systems of project participants and wider society. Additionally, many of the new ways of working that lean thinking brings already support the creation of a common understanding and could be harnessed to better effect. Based on a literature review and supported by case study examples the authors explore the nature of knowledge and understanding and position them within an eight flow model for construction production. The findings indicate a need to reconsider the development of a common understand for each project due to the tacit nature of experiential knowledge held within the project team and the specificity and complexity of the project environment. As a result effort is required to generate and maintain a common understanding throughout the project duration. The continued attention and action required to maintain this common understanding elevates it to a flow of equal status to those identified in Koskela’s flow production model thus increasing the number of flows to eight. A significant lean construction case study is revisited and examined to identify interventions undertaken to achieve this generation and management of common understanding thus demonstrating that this development already exists, albeit intuitively, as an element of “lean thinking”

Application of Lean Methods into the Customised Product Development Process of Large Power Transformers

The study conducts research on lean product development (PD) methodology and presents a case study of its practical application into a specific one-of-a-kind development of large power transformers. The demonstrated framework is the result of a 5-year intensive research that led to an extensive transformation of a traditional PD environment into a highly efficient process according to lean principles. Paper explains how lean PD integrates with robust, concurrent and smart design strategies in highly individualized PD business. A generalized framework of PD and design process renovation is presented, comprising three main fields of interest: Process & Tools, People, and Knowledge. A direct consequence of implied renovation are significant savings. Case-study company cut down engineering changes by 32 % in three year test period and experienced performance improvement between 25 % and 83 % across designated process indicators

On Knowledge-based Development: How Documentation Practice Represents a Strategy for Closing Tolerance Engineering Loops

AbstractKnowledge from multiple sources is required for defining tolerances in new product development (NPD). Successful outcomes in product development (PD) depend on the collective ability to integrate this knowledge into the product. Assessing variability and tolerance capabilities are essential parts of PD-knowledge as they represent limits of specifications with wide-ranging impact. Reducing the engineers time spend on (re)defining tolerances and searching for the right information can prevent substandard NPD performance in terms of quality, lead time, cost and product innovation. Hence, two topics of significant importance for achieving leanness (i.e., effectiveness and efficiency) in PD are towering tolerance knowledge and associated documentation practices. This paper presents the results of a survey among engineering professionals of two industrial companies made to study documentation and tolerance practices in different industrial environments. The results reveal similarities between the challenges that the companies face, including implementation of effective documentation (e.g. Knowledge-Briefs, A3 reports), visualization of physical relationship between product performance attributes and design parameters (e.g. trade-off curves) and the transfer of knowledge between projects for organizational learning. This paper makes a contribution to the body of knowledge related to (lean) NPD by documenting current industrial challenges and practices in achieving viable internal tolerance engineering routines and processes, along with the needs for documentation tools

Towards a holistic lean product development framework

Companies consider product development (PD) their competitive lever to survive in a technology-fuelled and fast-paced environment. Lean Product Development (LPD) is a promising concept currently being adopted by companies focusing on maximising customer value, shortening lead times, and reducing costs in PD. This research initially concentrates on developing a comprehensive LPD framework which subsumes existing concepts and supersedes them by including findings from the wider PD research area. The investigation then leads into understanding the highly-interwoven, yet underinvestigated, character of LPD to pave the way for its implementation into the complex knowledge-based PD environment. The deduced systematic implementation plan, which both provides an appropriate level of detail and accounts for the inherent complexities of LPD, supports companies in their struggle to embrace Lean practices in PD. The LPD framework is developed by employing a content analysis of existing concepts and integrating insights from the wider PD environment. The relationships between the framework’s elements are investigated using the results of a self-administered questionnaire embedded in a cross-sectional research design and complemented by the fruitful discussions found in literature. The insights into the inner workings of the framework are subsequently appropriated to formulate general recommendations and an effective implementation plan

Managing the Potential of Modularization and Standardization of MEP Systems in Industrial Buildings - Guidelines for improvement based on lean principles

Modularization and standardization (M&S) of MEP (mechanical, electrical, and plumbing) systems improve end customer value according to lean concepts and principles. However, the imple-mentation of M&S is challenged. This research includes three main parts

Set-Based Prototyping in the Context of the Configurable Virtual Product: The Construction of the Learning Value Streams (LVS) Model

RÉSUMÉ La présente thèse de doctorat est le résultat de sept années de recherche intervention dans les domaines de la conception et du développement de produits suivant le paradigme lean en aérospatial. Cette recherche action est motivée par la nécessité de développer les connaissances ainsi que les outils appropriés pour le développement de produits suivant l’approche lean (LPD pour Lean Product Development) et en particulier celle de l’ « ingénierie concourante fondée sur les options de conception » (SBCE pour Set-Based Concurrent Engineering) en aérospatial. Une telle nécessité se justifie par les facteurs socioéconomiques du 21ème siècle qui imposent des approches de conception et développement toujours plus robustes, résilientes, réactives, flexibles, innovantes et adaptables face aux fluctuations du marché et à la demande des consommateurs qui évolue rapidement, ceci afin de permettre aux compagnies de demeurer compétitives. L’objectif principal de la recherche, au vue de tels impératifs, est d’identifier, pour ensuite développer et intégrer dans un modèle holistique, les aspects, les caractéristiques et les catalyseurs essentiels des approches LPD et SBCE appliquées à l’industrie aérospatiale de façon à supporter l’implémentation à grande échelle de telles approches, et ce, dans une optique sousjacente de gestion de cycle de vie du produit (PLM pour Product Lifecycle Management). La planification et l’exécution du projet de recherche sont réalisées en respectant une méthodologie éprouvée en conception (DRM pour Design Research Methodology) afin de focaliser les résultats sur l’avancement des connaissances et de la pratique du LPD et SBCE en tant qu’approches de conception. La recherche apporte en conséquence des contributions majeures à ces champs d’étude tout en prescrivant une méthodologie de transformation des processus et outils de développement de produits dans l’industrie par le biais de l’implémentation du modèle de « chaines de valeur apprenantes » (LVS pour Learning Value Streams). Plus en détails, les contributions aux avancées scientifiques et pratiques dans le domaine vont comme suit : (1) La proposition d’un nouveau cadre d’analyse de la littérature SBCE, ainsi qu’une méthodologie de revue systématique fondée sur des données probantes; (2) L’avancement des connaissances théoriques et pratiques du LPD et SBCE des aspects les plus généraux aux plus significatifs; (3) L’avancement des connaissances théoriques et pratiques sur la modélisation et les structures de produit requises dans une optique de gestion de cycle de vie du produit----------ABSTRACT The work reported in this thesis is the result of seven years of participatory action research in the field of Lean Product Development (LPD) in aerospace engineering. This research is motivated by the necessity to develop understanding and support for practical implementations of lean product development and especially Set-Based Concurrent Engineering (SBCE) in industry. Such necessity is justified by 21st century compelling socioeconomic factors that demand robust, resilient, responsive, flexible, innovative, adaptable and lean product development processes in order for companies to stay competitive in rapidly changing markets. The main purpose of the research is to identify and develop the essential SBCE and LPD aspects, characteristics, features and catalysts as they relate to aerospace large-scale industrial product development in order to form a holistic model that can support practical implementations of LPD in industry from a product lifecycle perspective. A design research methodology (DRM) is used for planning and executing the design research project while ensuring that focus is placed on achieving progress with regards to understanding and implementation of SBCE and LPD as Design practices. As a result, this thesis work provides substantial contribution to understanding of LPD and SBCE and furthermore, entails valuable proposal for the practice in industry through the CCS model and the construction of the Learning Value Streams (LVS) model. Major contributions to the advancement of scientific knowledge and practice in the fields are as follows: (1) The proposal of a new SBCE dual analysis framework combined with an evidence-based systematic review methodology; (2) The advancement of theoretical and practical understanding of LPD and SBCE from the larger to the most significant aspects; (3) The advancement of theoretical and practical understanding of product models and product structure progression requirements for lean product lifecycle management; (4) the proposal of a new methodology, including new as-tested structure to support cross-collaboration during prototyping and testing in lifecycle management contexts; (5) The proposal of a new existential domain alongside the functional, technological and physical domains in order to address the lack of product modelling constructs and methodology when it comes to service or as-tested configurations, hardware testing transactions and prototype information tracking on the basis o

Lean Thinking For Lead-Time Reduction And Efficient Knowledge Creation In Product Development

There are many distinct differences between manufacturing process and Product Development (PD) process, so lean tools have to be customized to deliver results in the later domain. The main focus of this dissertation is to extend them to manage and improve the PD process in order to develop the product faster while improving or at least maintaining the level of performance and quality. For aforesaid purpose, value stream mapping (VSM) method is used to explore the wastes, inefficiencies, non-valued added steps in a single, definable process out of complete PD process. Besides numerous intangible benefits, VSM framework will help the development team to reduce the lead-time by over 50%. Next, a set of ten lean tools and methods is proposed in order to support and improve efficiency of the knowledge creation (KC) process. The approach establishes a KC framework in PD environment, and systematically demonstrates how these lean tools and methods conceptually fit into and play a significant role in enhancing the performance of KC process. Following this, each of them is analysed and appropriately positioned in a SECI (socialization-externalization-combination-internalization) mode depending on the best fit. Quick and correct KC at the right time aids in further improving the development lead-time and product quality. Such successful innovation is often associated with adoption and execution of all SECI modes within any PD phase. This dissertation attempts to argue with this general notion and to distinguish different PD phases\u27 affinity corresponding to distinct SECI mode. In this regard, an extended Fuzzy Analytic Hierarchy Process (EFAHP) approach to determine the ranking in which any PD phase is influenced from SECI modes is proposed. In the EFAHP approach, the complex problem of KC is first itemized into a simple hierarchical structure for pairwise comparisons. Next, a triangular fuzzy number concept is applied to capture the inherent vagueness in linguistic terms of a decision-maker. This dissertation recommends mapping the triangular fuzzy numbers (TFNs) with normal distributions about X-axis when the pessimistic value of one TFN is less than the optimistic value of other TFN (t23 ≤ t11). This allows us to develop a mathematical formulation to estimate the degree of possibility of two criteria as opposed to zero resulted by the use of the current technique in the literature. In order to demonstrate the applicability and usefulness of the proposed EFAHP in ranking the SECI modes, an empirical study of development phase is considered. After stringent analysis, we found that the combination mode was the mode that highly influenced the development phase

Lean product development: nothing new under the sun?

The concept of lean product development has attracted the attention of many scholars since its inception in the 1990s derived from practices at Toyota Motor Company. Key to this approach to new product development (NPD) are a few methods derived from lean production as well as longer established practices such as concurrent engineering. This makes one wonder whether lean product development is a new practice, a new method or an encapsulation of already existing methods at the time; this quest for the roots and tenets of lean product development, also in comparison with other methods for NPD, is the focus of this paper. This journey takes this propositional paper not only to the roots of lean product development and the context of its era of conception, but also to what this concept adds to other extant methods for NPD. In particular, this comparison draws out that other methods are trying to achieve the same objectives: the creation of products and services with value to the customer, the reduction of time-to-market and the efficient use of resources. This inference implies that managers of new product (and service) development can choose from a wider pallet of methods and approaches to enhance the performance of R&D and to connect better to manufacturing (including supply chains). Inevitably, this has implications for research on (lean) product and service development; hence, this paper sets out a research agenda based on the deliberations and gaps that have been uncovered in the discourse