Leannovazione R&D project management: processes

Technology Centre-ABB- ITALY P. Bertolotto - December 14st 2015 Leannovazione R&D project management: processes Copyright 2014 ABB. All rights reserved.

Agenda - Reasons of structured approach - R&D processes, methods and tools - The industrial development process - Gate model - Visual (Lean) development Oobeja method - Lesson learned March 23, 2016 Slide 2

Agenda - Reasons of structured approach - R&D processes, methods and tools - The industrial development process - Gate model - Visual (Lean) development Oobeja method - Lesson learned March 23, 2016 Slide 3

What is the ultimate purpose of developing a new product for a company? New product Environmental impact More innovative New application Business Portfolio completion New technology Gap covering More reliable More safety March 23, 2016 Slide 4

R&D project development flow Specifica Product di prodotto Spec Specifica TRS Tecnica Responsabile R&D PM di progetto R&D Feasibility Studio Preliminare Studies Progettisti e R&D Designer disegnatori R&D Disegni Dwgs Costruttivi Officina Workshop campioni prototyping Prototyping Prototipo Sala Test Lab Prove (sperimentale ed EMC) Development Prove di sviluppo Tests Retroacting actions based on development phase results R&D R&D ed Ingegneria and Engineering Disegni R&D Final definitivi DwgsR&D and Engineering Igegnerizzazione processes Certification Prove di tipo e certificazioni Tests Zero Serie Series zero

Agenda - Reasons of structured approach - R&D processes, methods and tools - The industrial development process - Gate model - Visual (Lean) development Oobeja method - Lesson learned March 23, 2016 Slide 6

New product development process: from creativity phase to the market The main phases to develop a new product: creative and innovative phase, the market and customer requirements, the potential development alternatives and the evaluation of the feasible solutions, new concepts validations, the production phase and the validation of the development results as they are the business process and production process Innovation Idea Selection Criteria: from Funnel to tunnel MRS TRS Planning Feasibility Development Product Qualification/Certification Review Industrialization Production validation Marketing Promotion Lesson learned March 23, 2016 Slide 7

Agenda - Reasons of structured approach - R&D processes, methods and tools - The industrial development process - Gate model - Visual (Lean) development Oobeja method - Lesson learned March 23, 2016 Slide 8

Gate Model

Parameters to assess the project efficiencies At the end of each Gate a document is released that assesses the project status by a negative/positive vote according to a trafficlight model. The main parameters on which is based the assessment are: On target product cost On time development time On budget according to the assigned budget Gate Assessor and Project Owner, according to the gate assessment, take the decision about the future of the project : go ahead go ahead with actions stop the gate and demote it Close the gate and put on-hold the project

Modello a Gate: modello universale Descrizione Una immobiliare investe nella realizzazione di un complesso residenziale Un privato vuole ristrutturare casa Una Amministrazione Comunale vuole costruire un Centro Sociale Si stila una specifica tecnica ed economica Si cerca un progettista che proponga una soluzione Si bandisce una gara per un progetto Viene fatto un progetto che soddisfa le richieste e/o applica deviazioni positive Il progetto viene approvato dagli enti preposti Si redigono gli esecutivi, si scelgono i materiali, le finiture, ecc. Si scelgono le ditte, si stila una piano (contratto) esecutivo Gate G0 G1 G2 G3 March 23, 2016 Slide 11

Modello a Gate: modello universale Descrizione Gate Si costruisce l opera G4 La si collauda e la si rende disponibile ai potenziali utilizzatori Si verifica dopo un tempo significativo: - Il costo effettivo - Il tempo di realizzazione effettivo - eventuali difetti dell opera Si verifica il ritorno d investimento G5 G6 G7 March 23, 2016 Slide 12

Agenda - Reasons of structured approach - R&D processes, methods and tools - The industrial development process - Gate model - Visual (Lean) development Oobeja method - Lesson learned March 23, 2016 Slide 13

Visual Development TC Dalmine contribution to the PPMV R&D Quality Initiative In order to contribute to the PPMV R&D Quality Initiative, Dalmine TC is proposing to apply the visual development method (generally called Oobeya method) to innovative projects In the next slides the results of a real experience and a few very common method concepts and theoretical benefits are presented March 23, 2016 Slide 14

Project development process Project goal: please refer to the improvement of something which is tangible and measurable (e.g. time, money); Four key indicators Timing: deviation from the planning Cost: deviation from the targeted value Development: deviation from the project budget Quality: number of project deviation from MRS or mistakes after G5 Measurable scale must be defined before project starting Gate model will be applied in parallel in order to guarantee the reporting process. March 23, 2016 Slide 15

Project development process Lean development applied to HySec project Pilot at Dalmine TC Target: develop 24 kv 630 A 16 ka integrated circuit breaker, line disconnector and earthing switch 4 KPIs Development Time: deviation from planning 20 % Product Cost: deviation from targeted value 2 % Development Cost: deviation from project budget 20 % Quality: no relevant claims by customers for 2 years from G5 date Detailed targets values released at G2 March 23, 2016 Slide 16 All the four KPIs have been achieved

Visual Development Oobeya: the big room overview March 23, 2016 Slide 17

Visual Development: Oobeya rules Mission must be clear to everybody. There is a common feeling of urgency. No title or qualification will drive the team but the leadership and the capability to take decision. If somebody delays, he must be helped by the team Discipline must be rigorous. Toll creative usage must be emphasized and promoted. Bureaucracy must be eliminate (no activity without any added value). The best data must be used also if they will be in rough type. There is a real consequence on the customer and on the team in case of delay. Frequently project team meeting should be done The meeting should be very short and effective No pending issues will be leave at the meeting end Face-mail on e-mail The meeting will flow from left to right (one way) March 23, 2016 Slide 18

Visual Development: Oobeya benefits Lead time and development time reduction Higher planning (timing) reliability Less long meetings and less bureaucracy The main information are visible to everybody (communication and sharing) Best comprehension and sharing of issues and criticalities with consequent risks reduction Knowledge sharing increased Quality enhancement (right the first time) Increasing of problem finding e problem setting tool Higher cooperation and best work atmosphere March 23, 2016 Slide 19 Easiest trade-off learning and solutions Simplification of project documentation

1. Innovation Concepts and methods to structured innovation. TrIz, Nine windows, etc. The risks of innovations. The patents as source of innovation. Breakthrough Innovation Incremental innovation Innovation perceived Random methods: Brainstorming Synectics Reframing -Lateral thinking - SCAMPER... Unstructured innovation Triz Nine Windows Forecasting Innovation Inspiration from nature: Biomimetics, Bionics, Biomimicry Taxonomy Technology & Technical Innovation Aesthetics innovation March 23, 2016 Slide 20

Creativity, innovation and future Technology is nothing. What s important is that you have a faith in people, that they re basically good and smart, and if you give them tools, they ll do wonderful things with them..creativity is just connecting thing because I did not know you couldn't do, I felt able to do it by Steve Jobs Creativity is the base of the innovation The innovation is the gate for the future March 23, 2016 Slide 21

Agenda - Reasons of structured approach - R&D processes, methods and tools - The industrial development process - Gate model - Oobeja - Lesson learned March 23, 2016 Slide 22

Project development process Lesson learned The Product Development by R&D in Industry is based on three main pillars: Competencies Product People March 23, 2016 Slide 23

March 23, 2016 Slide 24