Engineering Manufacturing Have Similarities and Differences Manufacturing Engineering Define Value Visible at each step, Harder to see defined goal emergent goals Identify Value Parts and nformation Stream material knowledge Make process Iterations are waste Iterations often flow beneficial Customer pull Driven by Takt time Driven by needs of enterprise Perfection Process repeatable Process enables without errors innovation and cuts cycle time Deborah Nightingale, MIT@ 2002 Source: Lean Aerospace Initiative
6 Deborah Nightingale, MIT © 2002 Process enables innovation and cuts cycle time Process repeatable without errors Perfection Driven by needs of enterprise Customer pull Driven by Takt time Iterations often beneficial Make process Iterations are waste flow Information & knowledge Parts and material Identify Value Stream Harder to see, emergent goals Visible at each step, defined goal Define Value Manufacturing Engineering Engineering & Manufacturing Have Similarities and Differences Source: Lean Aerospace Initiative
Engineering value is emergent Activities accumulate information eliminate risk, use resources Risk Process InfoOutcome Value Realized Time Adapted From Chase, "Value Creation in the Product Development Process, 2001 Deborah Nightingale, MIT@ 2002
7 Deborah Nightingale, MIT © 2002 Engineering Value is Emergent Adapted From Chase, “Value Creation in the Product Development Process”, 2001. Time Value Risk Info Activities accumulate information, eliminate risk, use resources Value Realized Process Outcome
Engineering Requires the Seamless Flow of Information and Knowledge Information can be an IT problem -solutions 25 No Database exist but are not Commonality easy o8 Knowledge is a bome 10 people problem requires Best practice communication- this 0 is hard! R&D Concept Concept Prelim. Detail Fab&test Sales Def. Asses Design Design o&S Program Phase From Hoult et al, "Cost Awareness in Design: The Role of Data Commonality, 1995 Deborah Nightingale, MIT@ 2002
8 Deborah Nightingale, MIT © 2002 Program Phase % of Programs Over Cost From Hoult et al., “Cost Awareness in Design: The Role of Data Commonality”, 1995. No Database Commonality Some Best Practice Engineering Requires the Seamless Flow of Information and Knowledge 0 5 10 15 20 25 30 35 R&D Concept Def. Concept Asses Prelim. Design Detail Design Fab&test Sales O&S Information can be an IT problem - solutions exist, but are not easy Knowledge is a people problem - requires communication - this is hard!
Communication Key to Flow and Pull Flow cannot be achieved until engineering processes move and communicate without errors or waiting 62% of tasks idle at any given time Task (detailed member company study) Task( Active 50-90% task idle time found Idle in Kaizen-type events(case studies Pull achieved when engineering cycle times are as fast or faster than the customer's need or decision cycle Deborah Nightingale, MIT@ 2002
9 Deborah Nightingale, MIT © 2002 Communication Key to Flow and Pull Flow cannot be achieved until engineering processes move and communicate without errors or waiting 62% of tasks idle at any given time (detailed member company study) 50-90% task idle time found in Kaizen-type events (case studies) Task Task Active Idle Pull achieved when engineering cycle times are as fast or faster than the customer’s need or decision cycle