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