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E-raamat: Toyota Product Development System: Integrating People, Process, and Technology

  • Formaat: 400 pages
  • Ilmumisaeg: 28-Oct-2020
  • Kirjastus: Productivity Press
  • Keel: eng
  • ISBN-13: 9781482293746
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  • Formaat: 400 pages
  • Ilmumisaeg: 28-Oct-2020
  • Kirjastus: Productivity Press
  • Keel: eng
  • ISBN-13: 9781482293746

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The ability to bring new and innovative products to market rapidly is the prime critical competence for any successful consumer-driven company. All industries, especially automotive, are slashing product development lead times in the current hyper-competitive marketplace. This book is the first to thoroughly examine and analyze the truly effective product development methodology that has made Toyota the most forward-thinking company in the automotive industry.

Winner of the 2007 Shingo Prize For Excellence In Manufacturing Research!

In The Toyota Product Development System: Integrating People, Process, and Technology, James Morgan and Jeffrey Liker compare and contrast the world-class product development process of Toyota with that of a U.S. competitor. They use extensive examples from Toyota and the U.S. competitor to demonstrate value stream mapping as an extraordinarily powerful tool for continuous improvement.

Through examples and case studies, this book illustrates specific techniques and proven practices for dealing with challenges associated with product development, such as synchronizing multiple disciplines, multiple function workload leveling, compound process variation, effective technology integration, and knowledge management.

Readers of this book can focus on optimizing the entire product development value stream rather than focus on a specific tool or technology for local improvements.

Arvustused

"If you're among the many who have been waiting for a definitive book about Lean Product Development, your wait is over. The Toyota Production System has become extraordinarily famous as well as widely admired and copied in companies around the world. Yet, its product development system is unquestionably as important for Toyota's success as is its production practices, if not more so. The quality performance and broad product appeal among an ever-widening spectrum of customers are undeniable and directly attributable to the efficacy of the company's product development and engineering organization. This book provides both the big picture context and the detail you'll need to understand the fundamental differences between conventional approaches and thinking toward development and Toyota's lean approach. Place this book on an easy-to-reach shelf - you will refer to it over and over, for a long time to come." John Shook President, TWI Network, Inc.,, Author, Learning to See, February 23, 2006

"Absolutely brilliant. This is the most important breakthrough in understanding Toyota's runaway success since Lean Thinking. It has long been common knowledge that most of the cost, quality and attractiveness of a product are determined in the development process, and that Toyota engineers its designs for customer value and lean manufacturing. This insightful book finally gives away the secrets of Toyota's Product Development System, and will allow you to create your own lean development process: read it, and there's no turning back." Freddy Balle & Michael Balle, Authors, The Gold Mine, February 23, 2006



"By combining Jeff Liker's comprehensive insights into the whole Toyota system with Jim Morgan's experience in product development plus his fine-grained investigation of the Toyota development system, they have finally put the whole puzzle together. All that remains is for you to study this volume carefully - and it does demand careful study because it presents a complete system integrating people, process, tools, and technology - and then to transform your own development system." From The Foreword By James P. Womack, Co-Author, The Machine that Changed the World, February 28, 2006

"Product Development is one of the key frontiers of lean thinking in the coming years. Learn how to turn the tables on the competition by reading this book." Daniel T. Jones, Chairman, Lean Enterprise Academy, UK, Co-author, The Machine that Changed the World, February 28, 2006



"How does Toyota do it? This book explores how, presenting both the big picture and providing great details. It describes the "chief engineer system" Toyota employs and discusses product development value stream mapping. It speaks to culture change and design technology. It's also rife with examples and case studies" Review

Foreword xv
Acknowledgments xvii
Preface xix
Section One: Introduction
The New Product Development Revolution
3(12)
The Next Competitive Frontier: The Product Development System
5(4)
Excellence in Product Development: The Next Dominant Core Competency
9(1)
Lean Product Development System: Linking Disciplines, Departments, and Suppliers
10(1)
Why Focus on Toyota?
11(1)
Learning from Toyota
12(3)
The Lean Product Development System Model
15(12)
A Sociotechnical System (STS)
15(12)
The Process Subsystem: LPDS Principles 1 to 4
17(4)
The People Subsystem: LPDS Principles 5 to 10
21(2)
The Tools and Technology Subsystem: LPDS Principles 11 to 13
23(4)
Section Two: Process Subsystem
Establish Customer-Defined Value to Separate Value-Added from Waste
27(12)
Customer-Defined Value Process at North American Car Company
28(1)
Customer-Defined Value Process at Toyota
29(3)
Program Leadership: The Chief Engineer Role
29(1)
Steps for Delivering Value to the Customer
30(2)
Case Example: Lexus Body Team Reduces the Margin for Error in Half
32(4)
Why This Is the First Principle
36(3)
Front-Load the PD Process to Explore Alternatives Thoroughly
39(28)
Front-Loading for the Design Factory: Creating the Context for Individual Program Development by Managing Product Platforms
41(1)
Derivative Vehicles Built on Existing Product Platforms
42(2)
Advanced Technology Planning
44(2)
Front-Loading Within an Individual Program: Styling and Engineering Feasibility
46(1)
Set-Based Concurrent Engineering
47(4)
Toyota Body and Structures Engineering---Kentou
51(2)
Standardizing Lower-Level Activities Enables Quick Problem Solving---An Example
53(1)
Application of Common Architecture and Principle of Re-use
54(1)
Evaluating and Deciding on Vehicle-Level Goals
55(1)
Toyota Production Engineering: The Simultaneous Engineer's Responsibilities
56(1)
SEs Must Hit Investment and Variable Cost Targets
57(2)
Mizen Boushi and Going to Production Plants
58(1)
Communicating with Functional Specialists
59(1)
The SE Submits the Plan
59(1)
Leveraging Digital Tools
59(1)
Early Problem Solving in Kentou: A Case Example
60(4)
Kozokeikaku (K4) Pulling the Pieces Together
64(1)
Right Person, Right Work, Right Time
64(3)
Create a Leveled Product Development Process Flow
67(32)
The Power of Flow
67(1)
Viewing Product Development as a Process
68(1)
Value Stream Mapping
69(1)
Seven Wastes in the Product Development Process
70(4)
There Are Really Three Ms
74(2)
Barriers and Facilitators of Flow: Insights from Queuing Theory
76(6)
Leveled Flow Starts in the ``Fuzzy'' Front End: Kentou and Flow
82(1)
The Role of Process Logic
82(1)
Workload Leveling, Cycle Planning, and Allocating Resources
83(2)
Staggering Vehicle Launches Using Common Platforms
84(1)
The Execution Phase of Product Development
85(1)
Cross-Functional and Within Functional Synchronization
86(2)
Examples of Cross-Function Synchronization
87(1)
Creating Flexible Capacity
88(2)
Detailed (Fundoshi) Scheduling to Head Off Unevenness
90(1)
Detailed (Fundoshi) Scheduling at the Functional-Organization Level
91(1)
Using Staggered Releases to Flow Across Functions
91(1)
Creating Process Flow in Nontraditional Manufacturing
92(1)
Establishing an Engineering Cadence and Cutting Management Cycle Time
93(1)
Using Jidoka and Poka-Yoke to Support Product Development Flow
94(1)
Pulling Knowledge Through the PD System
95(2)
Putting It All Together to Flow
97(2)
Utilize Rigorous Standardization to Reduce Variation and Create Flexibility and Predictable Outcomes
99(18)
Three Categories of Standardization
100(1)
Category One: Design Standardization and Engineering Checklists
101(3)
Category Two: Process Standardization
104(8)
Toyota's Standardized Process for Production Engineering
106(1)
Toyota's Die Engineering
106(1)
Process and Binder Development
107(1)
Toyota Lean Tool and Die Manufacturing
108(1)
Typical Time Frames for Lean Tool and Die Manufacutring
108(1)
Toyota Die Machining
109(1)
Toyota Die Construction
109(2)
Toyota Vehicle Assembly Engineering
111(1)
Category Three: Standardized Skill Sets/Competence
112(1)
Conclusion
113(4)
Section Three: People Subsystem
Create a Chief Engineer System to Lead Development from Start to Finish
117(100)
The Cultural Icon Behind the CE System
118(2)
A Tale of Two Chief Engineers: Lexus and Prius
120(11)
Lexus: A Chief Engineer Who Refused to Compromise
121(4)
Prius: A New Chief Engineer and New Engineering Process for a Twenty-first Century Car
125(6)
The CE Leadership Model
131(3)
NAC Product Development Manager: From Chief Engineer to Bureaucrat
134(1)
Group Facilitation at Chrysler
135(2)
Toyota CE System: Avoiding Compromises that Lead to Bureaucracy
137(80)
Build a Culture to Support Excellence and Relentless Improvement
217(24)
How Culture Can Stand Between You and Lean
217(3)
A Tool Is Not a Solution
220(1)
Contributing to Customers, Society, and Community
221(1)
Technical and Engineering Excellence Are Intertwined in the Culture
222(7)
Discipline and Work Ethic
224(2)
Everyday Kaizen
226(2)
Customer First Spirit
228(1)
Learning DNA
229(3)
Accountability and Responsibility
230(1)
Team Integrity
230(2)
Managing Upward, Downward, and Sideways: Hourensu Management
232(1)
The Right Process Will Yield the Right Results
233(1)
The Culture Supports the Process
234(3)
Leaders Renew the Culture
237(4)
Section Four: Tools and Technology Subsystem
Adapt Technology to Fit Your People and Process
241(18)
Five Primary Principles for Choosing Tools and Technology
241(2)
Technology in Lean Product Development
243(6)
Digital Engineering at Toyota
244(1)
Design Technology at Toyota
244(1)
Virtual Manufacturing and Digital Visualization at NAC
245(1)
Digital Assembly at Toyota
246(2)
Finite Element Analysis at NAC and Toyota
248(1)
Tools for Manufacturing Engineering and Tool Making
249(8)
Checklists and Standardization Tools at Toyota and NAC
249(1)
Solids Die Design: NAC Versus Toyota
250(1)
Pattern Making at NAC Versus High-speed Pattern Making at Toyota
251(1)
Die Machining: NAC Versus Toyota
252(1)
Tryout Presses: NAC Versus Toyota
253(1)
No Adjust Build at NAC Versus Functional Build at Toyota
254(1)
Three-dimensional noncontact measuring
255(2)
Adopting Technology to Enable Process
257(2)
Align Your Organization Through Simple, Visual Communication
259(20)
Chief Engineer's Concept Paper: An Aligning Document
260(2)
The Cross-Functional Obeya
262(1)
Alignment Tools
263(6)
Nemawashi at Toyota
264(1)
The Ringi System at Toyota
265(1)
Hoshin Management at Toyota
266(3)
Toyota's A3 Problem-Solving Tool
269(7)
Communication and Alignment at Toyota
276(3)
Use Powerful Tools for Standardization and Organizational Learning
279(18)
How Does Your Organization Learn?
279(1)
Knowledge Database at NAC: The Body Development Value Stream
280(1)
The Know-how Database at Toyota
281(5)
Competitor Benchmarking Reports at NAC
286(1)
Trade-Off Curves
284(1)
Decision Matrices
285(2)
Toyota Competitor Teardown and Analysis Sheets
287(2)
Standardization Tools at Toyota: Engineering Checklists, Quality Matrices, Senzu, Standardized Process Sheets
289(3)
The Role of Standardization and Learning Tools
292(5)
Section Five: Creating a Coherent Lean PD System
A Coherent System: Putting the Pieces Together
297(14)
Subsystem Integration: People, Process, Tools and Technology
299(1)
Identifying Value: Delivering Customer-Defined Value
299(1)
Enabling the Value Stream: Eliminating Waste and Variation
300(4)
Eliminate or Isolate Variation
302(1)
Flexible Capacity
303(1)
Creating Pull and Flow
304(2)
Enable Efficient Manufacturing
305(1)
Perfection: Building in Learning and Continuous Improvement
306(1)
Cross-Functional Integration
307(4)
Eliminating Waste in the Product Development Value Stream
311(22)
Product Development Value Stream Mapping (PDVSM)
312(13)
Addressing Some Differences Between PD and Manufacturing VSM
314(1)
Specific Challenges and Countermeasures for Mapping the PD Process
315(1)
Virtual data
316(1)
Longer timeframes
317(2)
Knowledge work
319(3)
Complex information flow
322(3)
Large, diverse group of specialists
325(1)
PDVSM Workshops
325(5)
Learning to See Product Development as a Process
330(3)
Getting to Culture Change: The Heart of Lean PD
333(20)
Develop an Internal Change Agent
335(1)
Get the Knowledge You Need
335(1)
Identify Manageable Work Streams to Understand PD as a Process
336(1)
Integration Mechanisms (Obeya/Design reviews)
337(1)
Enrollment of the Line Organization
338(1)
Start with Your Customer
339(1)
Grasp the Current State of Your Lean Product Development Process
340(3)
Driving to Real Culture Change
343(3)
People: The Heart of the Lean Product Development System
346(1)
A Roadmap for Lean Transformation
347(4)
Leadership and Building in Learning and Continuous Improvement
351(2)
Appendix: Applying Value Stream Mapping to a Product Development Process: The PeopleFlo Manufacturing Inc. Case 353(6)
Dr. John Drogosz
Bibliography 359(6)
Index 365(12)
About the Authors 377


James Morgan (Author) , Jeffrey K. Liker (Author)