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Lean Product and Process Development (LeanPPD)

 

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About the Project

The LeanPPD project addresses the need of European manufacturing companies for a new model that goes beyond lean manufacturing to ensure the transformation of an enterprise into a lean environment.

 

Project Aim

To develop a new model, based on lean thinking, that considers the whole product life cycle. The model will provide a knowledge based, user-centric, design and development environment to support value creation to the customers in terms of innovation and customisation.


Project Objectives

  • To identify value-adding activities in product development through current LeanPPD and best practice
  • To develop tools for LeanPPD value stream mapping and lean assessment
  • To develop an approach for knowledge acquisition, re-use and creation to enable a knowledge based environment for product development
  • To develop a set-based process and supporting tools to enhance the design of lean products
  • To develop a System Architecture Reference model to guide the implementation of KBE systems in LeanPPD
  • To Propose a route map for the incorporation of the model into differing levels of an organisation

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Methodology

The research methodology is based on the development of two main elements:

  1. The LeanPPD paradigm including the Lean Product & Process Development Model
  2. The development of its associated tools and guidelines

 

Lean PPD Methodology

 

The research concept of the LeanPPD paradigm is defined through extensive literature review, industrial requirements and performance measurements. This enables us to:

  • Identify industrial best practice
  • Propose a LeanPPD framework model
  • Identify key elements and the tools and techniques required to realise and deploy the research concept in industrial pilots

Inside the final LeanPPD Model the following tools, methodologies and frameworks will be included:

  1. A Lean Product & Process development assessment tool
  2. Developed to measure the performance of an enterprise considering human resources, technology factors and processes to measure the readiness and level of adoption of lean thinking principles in current industrial practices of product design and development (i.e. considering the entire product life cycle)
  3. A novel product development mapping tool for LeanPPD
  4. Developed to understand and maximise value from the customers’ point of view
  5. A knowledge-based engineering system architecture
  6. Enabling manufacturing companies to balance the need to react to value creation opportunities against the efficiency to deliver them effectively
  7. A Lean design concept framework
  8. To ensure the concurrent development of lean product design and it associated lean manufacturing system that is highly responsive to the changes of market requirements and production technologies

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Achievements so far

Several tools have been developed from the project, such as:

Imminent outcomes include

  • Lean Design Tool
  • SBCE Methodology
  • KBE Toolkit

The next phase of the programme is validation through Business Cases within each of the Industrial Partners.

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Research Team

Core members

Project Coordinator – Dr. Mikel Sorli
Technical Supervisor – Dr. Ahmed Al-Ashaab
Dissemination and Exploitation Manager – Prof. Marco Taisch

 

Team at WMG

Principal Investigator – Prof. Irene Ng
Mike James-Moore

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Publications/Research Outputs

By team at WMG

Martin, C., Keast, J. & James-Moore, M. 2010. The development of a tool and methodology for identifying and classifying waste within New Product Development. International Conference in Advances in Production Management Systems (APMS). Como (Italy).

Alam, R., Al-Ashaab, A., Shehab, E. & Martin, C. 2011. Value translation and representation for lean design. 9th International Conference on Manufacturing Research. Glasgow (UK).

Al-Ashaab, A., Shehab, E., Alam, R., Sopelana, A., Sorli, M., Flores, M., Taisch, M., Stokic, D. & James-Moore, M. 2010. The Conceptual LeanPPD Model. ISPE International Conference on Concurrent Engineering. Cracow (Poland).

Flores, M., Agrawal, M., Al-Ashaab, A., Stelling, M., Keast, J., Correia, A., Sopelana, A., Paris, A., Sorli, M. & Taisch, M. 2010. Gathering industrial requirements in the LeanPPD project to develop new tools towards a Lean Product and Process Development. ISPE International Conference on Concurrent Engineering. Cracow (Poland).

Flores, M., Cabello, A., Torredemer, L., Agrawal, M., Keast, J., Terzi, T. & Sopelana, A. 2011. Do enterprises implement a Process Architecture towards Lean in Product Development? A comparative study among large and small firms. 17th International Conference on Concurrent Enterprising. Aachen (Germany).

Sopelana, A., Sorli, M., Taisch, M., Al-Ashaab, A., Keast, J., Flores, M., Stokic, D. & Martinez, L. 2010. Applying Lean thinking concepts to New Product Development. International Conference in Advances in Production Management Systems (APMS). Como (Italy).

Others

Al-Ashaab, A., Flores, M., Khan, M., Maksimovic, M., Alam, R., Shehab, E., Doultsinou, A. & Sopelana, A. 2010. The industrial requirements of KBE for the LeanPPD model. International Conference in Advances in Production Management Systems (APMS). Como (Italy).

Flores, M., Diaz, D. L. & Tucci, C. 2010. Wheel of Change Framework towards Lean in Product Development. CIRP Design Conference. Nantes (France).

Flores, M., Diaz, D. L., Tucci, C., Al-Ashaab, A., Sorli, M., Sopelana, A. & Paris, A. 2010. Wheel of Change Framework towards Lean in Product Development. International Conference in Advances in Production Management Systems (APMS). Como (Italy).

Flores, M., Klinke, S., Tucci, C., Terzi, S., Al-Ashaab, A. & Sopelana, A. 2010. Identifying Lean Thinking Measurement Needs and Trends in Product Development: Evidence from the Life Sciences Sector in Switzerland. ISPE International Conference on Concurrent Engineering. Cracow (Poland).

Kerga, E., Melacini, M., Perego, A. & Taisch, M. 2011. Analysis of logistics performances of a VMI programme in an FMCG supply chain. International Conference in Advances in Production Management Systems (APMS). Stavanger (Norway).

Kerga, E., Taisch, M. & Terzi, S. 2011. Integration of sustainability in NPD process: Italian Experiences. International Conference on Product Lifecycle Management. Eindhoven (Netherlands).

Kerga, E., Taisch, M. & Terzi, S. 2011. Lean decisions making for sustainable product design and manufacturing. International Conference in Advances in Production Management Systems (APMS). Stavanger (Norway).

Kerga, E., Terzi, S. & Taisch, M. 2010. Set Based Engineering and Eco-efficient design selection at conceptual phase of product design and development process. International Conference in Advances in Production Management Systems (APMS). Como (Italy).

May, G., Taisch, M. & Kerga, E. 2011. Assessment of Sustainable Practices in New Product Design. International Conference in Advances in Production Management Systems (APMS). Stavanger (Norway).

Rossi, M., Kerga, E., Terzi, S. & Taisch, M. 2011. Lean Product and Process Development: a Learning Kit. International Workshop on Experimental Interactive Learning in Industrial Management. Espoo (Finland).

Rossi, M., Kerga, E., Terzi, S. & Taisch, M. 2011. Lean Product Development: Fact Finding Research in Italy. International Conference on Industrial Engineering and Systems Management. Metz (France).

Rossi, M., Kerga, E., Terzi, S. & Taisch, M. 2011. Proposal of a method to systematically identify wastes in New Product Development Process. 17th International Conference on Concurrent Enterprising. Aachen (Germany).

Rossi, M., Taisch, M. & Terzi, S. 2011. From Academic Innovation to Practical Application: the LeanPD Italian Community. International Conference in Advances in Production Management Systems (APMS). Stavanger (Norway).

Sorli, M., Vidal, R., Cebrian-Tarrason, D., Sopelana, A. & Chulvi, V. 2009. Product Eco-Innovative Design based on the Knowledge. CIRP Design Conference. Cranfield (UK).

Stokic, D. & Sorli, M. 2009. Tools for Collaborative Work on Lean Innovation. 2nd ISPIM Innovation Symposium. New York (USA).

Taisch, M., Corti, D. & Terzi, S. 2010. Proposal of a Performance Measurement System for a lean-oriented NPD Process. International Product Development Management Conference. Murcia (Spain).

Taisch, M., Corti, D. & Terzi, S. 2010. Towards a Performance Measurement System for lean-oriented NPD processes. CIRP Design Conference. Nantes (France).

Taisch, M., Jacopo, C., Kerga, E. & Terzi, S. 2010. Lean Product Development Business Game, a Conceptual Work. International Workshop on Experimental Interactive Learning in Industrial Management. Milan (Italy).

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Funding

LeanPPD is part of the European Seventh Framework Programme (FP7), receiving €7.8 million EU funding.

Project timeframe

February 2009 – February 2013

 

Website

 

 

Latest Newsletter (PDF Document)

 

 

Project Partners

Cranfield University
Ecole Polytechnique Fédérale de Lausanne
Fundación Labein Tecnalia
Institute for Applied Systems Technology Bremen
WMG, Warwick University
Politecnico di Milano
Indesit
Rolls-Royce
Sisteplant
Sitech
Visteon
Volkswagen Group
 
 
 

Project Poster


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