Lean TRIZ : how to dramatically reduce product-development costs with this innovative problem-solving tool PDF
Preview Lean TRIZ : how to dramatically reduce product-development costs with this innovative problem-solving tool
$ Business & Management / Lean Methods / Problem Solving H $ $ a r r in g to $ n Lean TRIZ How to Dramatically Reduce $ Product-Development Costs with This $ Innovative Problem-Solving Tool $ $ Consumers want products and services faster, better, and cheaper, and companies strive to reduce product life cycles from years to months to days. $ $ Lean TRIZ is a new workshop-based process that brings together teams to $ focus on specific processes, evolutionary product designs, and improvement opportunities. It combines the insight of TRIZ, the powerful problem-solving $ technique, with the simplicity of Value Engineering, EXPRESS, or FAST methodologies. The Lean TRIZ Methodology (LTM) approach is defining solutions in hours, not weeks or months. Classic TRIZ was designed for very L difficult product design problems. Lean TRIZ has a heavy focus on processes. e It is able to reduce the cumbersome TRIZ 39 x 39 matrix down to a 3 x 41 matrix. a n Lean TRIZ: How to Dramatically Reduce Product-Development Costs with This Innovative Problem-Solving Tool provides insight on how to T reduce costs for optimum performance. By combining TRIZ’s simplest concepts with those in the EXPRESS methodology (used by Ford and Ernst & R Young), you can apply this innovative methodology to new concepts that are I not traditionally applicable to the TRIZ methodology. This book also: Z • Offers a two-day problem analysis cycle including management approval • Delivers revolutionary and proven approaches to define new product designs • Satisfies two important performance-improvement needs that every organization faces: 1. Process-related improvement opportunities How to Dramatically Reduce Product-Development 2. Design-related improvement opportunities Costs with This Innovative Problem-Solving Tool Y291121 ISBN-13: 978-1-1382-1677-8 90000 9 781138 216778 Lean TRIZ How to Dramatically Reduce Product-Development Costs with This Innovative Problem-Solving Tool The Management Handbooks for Results Series Lean TRIZ: How to Dramatically Reduce Product-Development Costs with This Innovative Problem-Solving Tool H. James Harrington (2017) Change Management: Manage the Change or It Will Manage You Frank Voehl and H. James Harrington (2016) The Lean Management Systems Handbook Rich Charron, H. James Harrington, Frank Voehl, and Hal Wiggin (2014) The Lean Six Sigma Black Belt Handbook: Tools and Methods for Process Acceleration Frank Voehl, H. James Harrington, Chuck Mignosa, and Rich Charron (2013) The Organizational Master Plan Handbook: A Catalyst for Performance Planning and Results H. James Harrington and Frank Voehl (2012) The Organizational Alignment Handbook: A Catalyst for Performance Acceleration H. James Harrington and Frank Voehl (2011) The Management Handbooks for Results Series Lean TRIZ Lean TRIZ: How to Dramatically Reduce Product-Development Costs with This Innovative Problem-Solving Tool How to Dramatically Reduce H. James Harrington (2017) Product-Development Costs with Change Management: Manage the Change or It Will Manage You Frank Voehl and H. James Harrington (2016) This Innovative P roblem-Solving Tool The Lean Management Systems Handbook Rich Charron, H. James Harrington, Frank Voehl, and Hal Wiggin (2014) The Lean Six Sigma Black Belt Handbook: Tools and Methods for Process Acceleration Frank Voehl, H. James Harrington, Chuck Mignosa, and Rich Charron (2013) The Organizational Master Plan Handbook: A Catalyst for Performance Planning and Results H. James Harrington and Frank Voehl (2012) The Organizational Alignment Handbook: A Catalyst for Performance Acceleration H. James Harrington and Frank Voehl (2011) By Dr. H. James Harrington CEO, Harrington Management Systems CRC Press Taylor & Francis Group 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL 33487-2742 © 2017 by Taylor & Francis Group, LLC CRC Press is an imprint of Taylor & Francis Group, an Informa business No claim to original U.S. Government works Printed on acid-free paper Version Date: 20160915 International Standard Book Number-13: 978-1-138-21677-8 (Hardback) This book contains information obtained from authentic and highly regarded sources. Reasonable efforts have been made to publish reliable data and information, but the author and publisher cannot assume responsibility for the validity of all materials or the consequences of their use. The authors and publish- ers have attempted to trace the copyright holders of all material reproduced in this publication and apolo- gize to copyright holders if permission to publish in this form has not been obtained. If any copyright material has not been acknowledged please write and let us know so we may rectify in any future reprint. Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, reproduced, trans- mitted, or utilized in any form by any electronic, mechanical, or other means, now known or hereaf- ter invented, including photocopying, microfilming, and recording, or in any information storage or retrieval system, without written permission from the publishers. For permission to photocopy or use material electronically from this work, please access www. copyright .com (http://www.copyright.com/) or contact the Copyright Clearance Center, Inc. (CCC), 222 Rosewood Drive, Danvers, MA 01923, 978-750-8400. CCC is a not-for-profit organization that provides licenses and registration for a variety of users. For organizations that have been granted a photocopy license by the CCC, a separate system of payment has been arranged. Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation without intent to infringe. Visit the Taylor & Francis Web site at http://www.taylorandfrancis.com and the CRC Press Web site at http://www.crcpress.com I dedicate this book to my loved ones who have passed away: my father, Frank, my mother, Carrie, my friend, Joe, and my wife, Marguerite. There is just no way to fill the void that was left in my life when God decided to take them away. Contents Preface ....................................................................................................xi Acknowledgments ............................................................................xxiii About the Author. ...............................................................................xxv Books by H. James Harrington ....................................................... xxvii About the Series .................................................................................xxxi Chapter 1 Introduction to LTM ..........................................................1 Introduction ..................................................................................1 Five Levels of Invention ...............................................................3 Why LTM Is Different ..................................................................7 Summary .......................................................................................8 Chapter 2 Five Special LTM Methodologies ......................................9 Introduction ..................................................................................9 VE and Value Analysis .................................................................9 SPI Methodology ........................................................................14 SPI Phase I—Planning ...........................................................15 SPI Phase II—Analyzing .......................................................16 SPI Phase III—Streamlining the Process ...........................23 Apply the Streamlining Approaches ..............................23 Lean .............................................................................................30 TRIZ .............................................................................................35 Two Common Approaches to Using the TRIZ Contradiction Matrix ...........................................................44 Patterns of Evolution ............................................................46 Lean Process TRIZ .....................................................................50 Summary .....................................................................................63 Chapter 3 Starting an LTM Program ...............................................65 Introduction ................................................................................65 Selling LTM to Your Organization ..........................................67 LTM Key Roles and Responsibilities .......................................68 vii viii • Contents LTM Facilitator/Leader and Team Members’ Responsibilities .......................................................................69 Internal LTM Facilitators ......................................................73 Preparation and Follow-Up ..................................................74 Summary .....................................................................................75 Chapter 4 Phase I—Identifying the Opportunities .........................77 Introduction ................................................................................77 Activity 1: Identifying the Need ...............................................78 Communication .....................................................................81 Activity 2: Using the S-Curve ...................................................81 Activity 3: Other Ways to Identify LTM Projects ..................85 Activity 4: Screening and Prioritizing Potential LTM Projects .........................................................................................87 Prioritization ..........................................................................87 Management Selection Approach ..................................88 Two-Level Analysis ..........................................................88 Weighted Selection Approach .........................................89 Summary .....................................................................................91 Chapter 5 Phase II—Preparing for the Workshop ..........................93 Introduction ................................................................................93 Activity 1: Define the LTM Project Sponsor ...........................94 Activity 2: Hold a Contracting Meeting ..................................95 Key Elements of an Effective Meeting ..............................101 Key Points Made during the Contracting Meeting ........104 Activity 3: Conduct a Planning Meeting ...............................104 Holding the Planning Meeting ..........................................105 Filling Out the Situation Questionnaire ...........................109 Activity 4: Collect Relevant Data to Prepare for the Workshop ......................................................................109 Summary ...................................................................................111 Chapter 6 Phase III—Conducting the Workshop ......................... 113 Phase I: Identifying Improvement Opportunities ...............118 Activity 1: Introduction ......................................................118 Contents • ix Task 1: Introduction and Business Overview .............118 Task 2: Present an Overview of LTM ...........................118 Phase II: Preparing for the Workshop ...................................119 Activity 2: Develop the As-Is Model .................................119 Task 3: Review Situation Questionnaire Results and Agree on Root Causes and/or Major Contradictions Related to the Improvement Opportunity .....................................................................119 Task 4: Refining the Process Flowchart or Reviewing the Current Product Specifications ......121 Task 5: Refining the As-Is Matrix ................................123 Phase III: Conducting the Workshop ...................................124 Activity 3: Start Workshop and Define Root Causes .....124 Task 6: Identifying Issues, Opportunities, Problems, Root Causes, and Major Contradictions that Were Not Covered in Task 5 .................................124 Task 7: Prioritizing the Issues, Opportunities, Problems, and Root Causes ...........................................133 Phase III: Conducting the Workshop ....................................135 Activity 4: Define Potential Improvement Options ........135 Task 8: Defining and Quantifying Improvement Action for Root Causes ...................................................135 Phase III: Conducting the Workshop ....................................143 Activity 5: Quantify Improvement Opportunities..........143 Task 9: Prioritizing and Classifying Improvement Action Items .....................................................................143 Task 10: Quantifying and Qualifying Potential Improvement Solutions ..................................................144 Phase III: Conducting the Workshop ....................................155 Activity 6: Management Review and Approval ...............155 Task 11: Preparing the Sponsor’s Presentation ...........155 Task 12: Presenting to the Sponsor(s) ...........................157 Task 13: Summarize the Results and Document Them .................................................................................161 Summary ...................................................................................162
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