MIT的精益生产工程方法 英文PDF27

LeanEngineering:LeanBeyondtheFactoryFloorAFrameworkforLeanEngineeringMarch24,1999HughMcManusCo-Lead,ProductDevelopmentFocusTeamLAI-MITResearchSponsoredByLAIPDMcManus032499-2©1999MassachusettsInstituteofTechnologyLeanAerospaceInitiativeStepsinLeanThinking(WomackandJones)UnderstandProcessEliminateWasteRadicalChange
Preciselyspecifyvaluebyspecificproduct
Identifythevaluestreamforeachproduct
Makevalueflowwithoutinterruptions
Letthecustomerpullvaluefromtheproducer
PursueperfectionPDMcManus032499-3©1999MassachusettsInstituteofTechnologyLeanAerospaceInitiativeTheQuestionDoleanconceptsfamiliarintheproductionworldapplytoproductdevelopmentand/orotherengineeringprocesses?
Manufacturing–Materialflows–Physicaltransformation–Rawmaterial-finishedproduct
Productdevelopment–Whatflows?–Whattransformationsareperformed?–Whatarethe“raw”and“finished”statesforaproductdefinition?PDMcManus032499-4©1999MassachusettsInstituteofTechnologyLeanAerospaceInitiativeProductDevelopmentValueStream(PDVS)LAIInitiative
MITworkinggroup
Industry/Governmentworkshops
Continuingvirtualworkinggroups
~9facultyandstaff,~11students,~40industry,~10governmentImportantproblemUniquecooperativeeffortIdealapplicationoftheLAIconceptPDMcManus032499-5©1999MassachusettsInstituteofTechnologyLeanAerospaceInitiativeResults
LeanconceptsDOapplytoPD
Mustbecarefullyre-interpreted,modified
Keyinsight:informationflowplaystheroleofmaterialflow
Keybarrier:defining/measuringValueProduct:LeanEngineeringFrameworkPDMcManus032499-6©1999MassachusettsInstituteofTechnologyLeanAerospaceInitiativeLeanEngineeringFramework1StartwiththeBigPicture2DefineProblemanditsBoundariesandInterfaces3DefineValueintheaboveContext4MaptheInformationStreams5IdentifyandEliminateWaste6EnableFlowandLookforOpportunitiesforRadicalChangeAcollectivewisdomproductToolsexist/underdevelopmentApplicationsunderwayatmanyindustrysitesPDMcManus032499-7©1999MassachusettsInstituteofTechnologyLeanAerospaceInitiative1StartwiththeBigPictureMarketDevelopmentStreamProductDevelopmentStreamRealizationStreamDeployment&SupportStreamProductLife-cycleValueEnterpriseValueProfitPDMcManus032499-8©1999MassachusettsInstituteofTechnologyLeanAerospaceInitiativePDintheBigPicture
PDembeddedin:–ProductLifetime–SupplyChain–(Lean)Enterprise
PDdeliversvalueindirectly–Mustpasstomanufacturing,sustainment,upgrades,beforebeingrealizedbyenduserorotherbeneficiary
PDhasverylargeleverageontotallifecyclevalueComplexitymustbecapturedbycorrectdefinitionsofproduct,process,andinterfacesPDMcManus032499-9©1999MassachusettsInstituteofTechnologyLeanAerospaceInitiative2aDefineProduct
Canbeentiresystem
Oftensub-component,upgrade,service,etc.
Carefullydefineproduct–Physicalboundaries–Functionalboundaries–PhysicalandfunctionalinterfacesPDMcManus032499-10©1999MassachusettsInstituteofTechnologyLeanAerospaceInitiative2bDefineProcess
Definerangeofactivitiestobeconsidered
Defineprocessinterfaces,intermsofinformationprocessstartsandendswith–Inputs(requirements,constraints,etc.)–Outputs(designblueprints,manufacturingplans,supplychainplans,verificationdocuments,etc.)
Wronginterfaces=wrongproblemdefinitionInitiativeProduct:GenericlifecycleprocessmapPDMcManus032499-11©1999MassachusettsInstituteofTechnologyLeanAerospaceInitiativeProductLifeCycleProcessCustomerRequirements(OperationalRisk)Co.Bus.PositionConstraintsStrategiesSystemsRequirementsProgramAttributesDesignToBuildTo(DesignRisk)(ManufacturingRisk)QualDesign(PerformanceRisk)DesignStandardsProductionStandardsSupportStandardsCustomerValueCustomerPerceivedRiskCo.ValueBarriers•Training•Measurements•CultureHardwareSupportedOperationalSystemsSystemDef’nPreliminaryDesignFAITDetailDesignProductionSupporttimePDMcManus032499-12©1999MassachusettsInstituteofTechnologyLeanAerospaceInitiativeSub-ProcessInputsandOutputsPreliminaryDesignInputsSystemRequirementsOutputsDesign-toPackage•SystemRequirementsDocument•CostTargets•SubsystemSpecs•SystemInterfaces•TestPlans•SystemConcepts(Mock-UpLayouts)•ManufacturingConcepts•ProducibilityAssessment•BlueBold=Customer•BlackBold=CompanyConstraintsandStrategies•LessonsLearned•ResearchandDevelopment•CommercialOffTheShelf(COTS)•CompanyStandards•ManufacturingStandards(Make/Buy)•AcceptanceandTestStrategy•TradeStudies(DesignRisk)PDMcManus032499-13©1999MassachusettsInstituteofTechnologyLeanAerospaceInitiative3DefineValueBarriers:Totallife-cyclevaluedefinitionValueatendofPDisnotrealizedyetMarketDevelopmentStreamProductDevelopmentStreamRealizationStreamDeployment&SupportStreamProductLife-cycleValueEnterpriseValueProfitPDMcManus032499-14©1999MassachusettsInstituteofTechnologyLeanAerospaceInitiativeTotalLife-CycleValue
ProductDevelopmentmustconsider“Big-Picture”definitionofvalue
CustomerValue–Performance(inc.availability,other“ilities”)–Cost(purchase,maintenance,upgrades,disposal…)–Timeliness(design,production)
EnterpriseValue–Synergieswithotherproducts–Preserving/enhancingcorecompetencies–Stakeholders:workforce,stockholders,etc.Toolsavailable;seeSlack(1998SDMThesis)PDMcManus032499-15©1999MassachusettsInstit