Lean Product Design:

Slashing Product Cost Through Value Engineering

The product cost reduction process represents one of the most complex, challenging, and poorly understood activities in business. However, reducing manufacturing cost is the fastest and surest way to achieve a measurable increase in profits.

This two-day intermediate level workshop presents a comprehensive set of practical, easily applied techniques for reducing the manufacturing cost of any product - including products that are still in development!

Workshop participants will learn how to apply these powerful techniques to real products, in real time, with high efficiency. The workshop follows the timeline of a typical product cost reduction project, from initial idea generation to product qualification and launch. Workshop participants will learn to dramatically reduce overall product cost through superior design and the creation of synergies between products. By the conclusion of this workshop participants are able to quickly craft a cost reduction strategy that is optimal for their products and markets.

These techniques require minimal organizational change, and will yield bottom line results very quickly. In addition to slashing manufacturing costs, your products will also better capture the customer’s perception of value. Reducing product cost is an essential step in your journey toward Lean product development excellence.

Like most Lean Solutions workshops, Lean Product Design combines classroom theory with practical exercises and case study simulations to reinforce the training. However, unlike most of our Lean Solutions, the theories presented during the workshop will not be directly applied to one of your products during the course.

• Understand the true cost build-up of any product
• Utilize twenty cost "levers" to perform cost-reduction trade-offs
• Improve customer communication and value capture
• Capture synergy across product lines through flexible platform strategies
• Eliminate design waste through value engineering
• Implement a simplified version of Toyota's 3P process
• Use six-sigma based tools to reduce variability and scrap
• Reduce touch labor and materials through Design for Manufacturing and Assembly (DFMA)

       Day One

• The Business of Lean Design
  • Screening for Profitable Products
  • Defining a Target Cost
  • Twenty Levers for Product Cost
• Capturing the Voice of the Customer
• Platform-Based Cost Reduction
  • Platform Strategies
  • Modular / Scaleable Design
  • Mass Customization

       Day Two

• Value Engineering
• Production Process Preparation (3P)
• Toyota's 3P Process
• The "How's it Built" Review
• Six-Sigma and DFMA Methodologies
• Lean Self-Assessment and Kaizen Tools

For more information on this workshop, including pricing, please contact us at (949) 241-6242, or send and email to contact@leansolutions.info.