Oehmen, Josef

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Research by Jin Kato - Contact: Jin Kato (Graduate Student), Massachusetts Institute of Technology, Department of Mechanical Engineering, Prof. Warren Seering jkato@mit.edu, Phone: +1-(617)-304-6733, MIT, 77 Massachusetts Av., Room 3-441, Cambridge, MA 02139 Task #1(5day)Task #1 (5day)Task #3Group AGroup B#1 Re (3day)Task #2Task #5Task #4Task #2 (5day)Task #4 (5day)WaitingInventory (3day)Hand-off Hand-offHand-offReworkTask #3 (5day)Task #5 (5day)Task #6Task #6 (5day)Wasted Time [hour]4 1062684.255.5 13.3 360100200300400500600700Waiting(PeopleWaiting)OverProcessingInventory(Informationin Buffer)MotionReworkHand-offsDefectiveInformationWaste Driver•  identify and measure the waste drivers in their teams’ processes; •  identify root-causes and measure their impacts on PD Processes; •  and finally, learn the best thing to pursue to improve their PD processes.  - help PD project managers  Goal of This Study: Preliminary Result from One  of the Investigated Project: Tool 1: Swim-Lane VSM • Helps Project Managers identify and measure Waste Drivers. • Waste Driver – Wasted Cost • Waste Driver – Root Cause • Root Cause – Wasted Time • Root Cause – Wasted Cost Other analysis will include the following graphs: • VSM, Waste Drivers and Root-Cause Analysis Chart have made it possible to identify both root causes of low PD performances and their quantitative impact on PD performances. Preliminary Conclusion: Study of Industrial PD projects Tool 2: Root-Cause Analysis Chart The analyzed period is the first two months out of 12-month PD project  -- more waste is expected to be detected in the later phases of the project.  7Root CausesCausesWaste (Low Performance) DriverVersion 3.4as of  1/54. Over Processing (2/3)4. OverProcessingDesigner’s Unconsciousness of GoalUnclear/Shifting GoalTardy InformationTransferInsufficient Pervasion of Goal InformationComplex Organizational StructureOutsourcingScattering LocationsComplex Hierarchy Structure of OrganizationDesigning FeaturesThat is Not Specifiedby Specification(Different from Spec.)InsufficientTime to Read/Examine/ReleaseInformationLimited Resources (1)System Over UtilizationLocal OverUtilizationNo Level SchedulingLimited Resources (2)Limited Qualifications of DesignersInsufficientTimeLack of Measurement of Designers’Achievements In Terms of GoalComplex Organizational Structure Scattering LocationsOutsourcingSpatial/ Structural BarrierComplex HierarchyStructure of OrganizationSpatial/ StructuralBarrierContinued fromprevious pageSlack (or Buffer) Time Becomes Self-FulfillingProphesyPoor Buffer Allocation Distribution of BuffersTo Every TaskNo Incentivefor Early Finish Impractical Incentive /Measurement SystemPoor Schedule/ Progress ControlFunctional OrganizationFunctional OrganizationEndogenousFactorsExogenousFactorsHighly Competitive MarketInstability of MarketRisk-Taking StrategyExistence ofUncertaintyTardy DecisionProcess Inadequate Scheduling Technique Inadequate Decision ProcessBtoBBtoCCustomer’s PoorUnderstanding of The MarketLow TRL Poor Understanding ofCurrent TechnologyInstability of MarketHighly Competitive MarketInconsistency in Customer’s DecisionInadequate  (Too Long)Development TimeComplexityof the Product Lack of ModularityNature of the ProductPoor Marketing Inadequate Marketing MethodLack of Feedback LoopUnderestimation ofDevelopment CostLack ofFeedback LoopLack of DFMLack of Concurrent EngineeringWaterfall Process withoutProper PrototypingTechnological Uncertainty UnderbidPerfectionist EngineerNow contains about 300 patterns of wasteful PD processesHelps Project Managers identify root causes of waste. • Visualizes Waste Drivers effectively. Have been applying VSM, Waste Drivers and Root-Cause Analysis Chart to three complicated PD projects in two big manufacturing companies.  • Company A: an American company developing test and measurement devices.  • Company B: a Japanese electric giant. Develop ideas and methodologies of Lean PD into tools and processes that can: - be applied to various PD organizations regardless of cultures and products. VSM and Root-Cause Analysis Chart have been developed, tested, and improved through intensive interviews with both project managers and engineers. Waste in Product Development - Study of Industrial PD Projects -  Jin Kato, MIT    March 22, 11:25-11:40 

Waste in Product Development

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Waste in Product Development

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