Improving NPI Effectiveness using Lean Thinking. Webinar 6 th October 2015
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1 Improving NPI Effectiveness using Lean Thinking Webinar 6 th October 2015
2 Everyone will be muted so that only the presenters will be heard. The presentation will be followed by a Q&A session. Please type your question in the question box. Recording will be made available after the webinar on the Industry Forum website. If you are experiencing any technical problems please call us on
3 Introduction Presenters: Dave Durbin & Ian Ford Industry Forum NPI Engineers Topic: Improving New Product Introduction using Lean Thinking Typical NPI Process Effectiveness Results Applying Lean thinking to NPI NPI process structure and adherence Enabling NPI process effectiveness
4 Audience Feedback Is Lean applicable to NPI? a) Yes, completely b) Some Lean principles are relevant c) No, not at all d) Never used Lean
5 Are you normal?
6 NPI Assessment Results Assessment scores show: Average score vs own target = 51.3% Average score vs World Class = 37.5%
7 Simplifying NPI Process x People x Results = Effectiveness Organisational Capability Strategic Maturity 5 Training and coaching 5 Capability development Process Maturity Ineffective process (variation in results) System development Chaotic process Effective and efficient process Inefficient process Process development Organisational Maturity Process Performance Bubble (success not necessarily World Class sustainable) Strategy development Struggling Engine racing (doing things right, but not doing the right things) Organisational Capability
8 Typical NPI improvement approach Fixing leaks Repairing drains Mending door Treating timbers What everyone sees in terms of the NPI process
9 What is the real situation? Door damaged Foundations are not solid!
10 Applying Lean to NPI
11 No structured process
12 No structured process Reliant on individuals No standards to improve Waste inherent in activity
13 Remember Tim Wood Transportation Inventory Motion Waiting Overproduction Over-processing 7 Wastes Defects
14 Can 5S and visual methods be applied to NPI?
15 Process not followed
16 Audience Feedback How do you know if your NPI process is followed? a) Don t check b) Audit process adherence c) Use results to judge adherence d) Measure gate adherence
17 Process not followed Not cross-functionally agreed Conflicting priorities Too complicated No measurement Poor senior level support
18 Process not as effective as we d like
19 Process not effective Overprocessing Strategy not linked to procedures Measures not in place Data available but no meaningful analysis to drive improvement
20 Audience Feedback How do you currently improve your NPI process? a) No improvement occurs b) Informal activity after an unsuccessful project c) Informal activity after every project d) A structured approach after every project e) A structured approach continuously as lessons are learned
21 How do we improve NPI? 5 Principles of Lean
22 1. Define Value
23 2. Map Value Stream
24 3. Create Flow
25 4. Establish Pull
26 5. Pursue Perfection
27 Advantages of applying Lean to NPI Reduced project leadtime Competitive advantages Customer confidence and ability to manage customer Standardising product modules design, relating similar features to FMEA etc.
28 Conclusions
29 Remember the lean basics Be data driven highlight and drive priority of improvement opportunities Set clear standards allow sharing of best practice and inclusion of learning from experience Organise the workplace (5S) ensure all tasks and information are required and organised efficiently Use visual management allow progress and status to be seen by all stakeholders to prompt correct reactions Make work flow ensure all activities are completed effectively and at the right time
30 For more information
31
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