A Methodology for Assessing Leanness in NPD Process

Abstract

Leanconceptsareroutinelyusedinmanufacturingbutarestillrelatively new to New Product Development (NPD) process. If manufacturing can be mod- eled as flow of material, an analogous model for NPD process would be flow of information. This paper addresses the issue of eliminating wastes in new product development process by bringing lean concepts through an assessment system. The paper first defines wastes in the context of NPD process. A large number of waste drivers which add to wastes in any NPD process are identified. Similarly lean enablers and lean tools which if implemented can reduce wastes are also identified. A model connecting wastes and lean enables is arrived which gives a holistic picture of relationship to address and assess wastes in any NPD process. In order to measure the effectiveness of NPD process five lean performance measures are used which include design cost overrun, product cost overrun, schedule overrun, knowledge capture and customer satisfaction. Industrial inputs are used to arrive at assessment system proposed in this work and a further feedback from industry is used to enrich the assessment system after it is developed. Though the proposed system is developed for machine tool development process, it is generic in nature and can be used to assess any new product development activity.