ADVANCED NEW PRODUCT DEVELOPMENT
This DFM section is the most effective and practical class available because:
So the most Advanced NPD course will need more than the usual "canned material taught by staff trainers" to only teach engineers guidelines using tools that may use software that look for “opportunities” after something is designed, which is discouraged, as shown in the articles “Why it is so hard to reduce cost or "implement" DFM after design” at http://www.halfcostproducts.com/how_not_to_lower_cost.htm and 7 Reasons Why “Cost Reduction” Attempts after Design Doesn’t Work;' at: http://design4manufacturability.com/cost_redu ction.htm
Finish Design in Half the time to Stable Production with thorough up front work, which is a unique theme of this course.
For more on the right graph, see the article "Time to Innovate"
For hyper-links to the explanations of how these work, go to the article on half-cost-products.
The overhead categories that can be reduced 10 times do generate so little overhead cost that they should not be charged any overhead at all, thus ensuring that those cost savings will make it to the selling price of the products designed by the principles presented only in this course.
Many designs will work, but only one will be the lowest cost.
Since the course presents many new ways (above) to proactively design substantially lower product costs, that can eliminate the common practice of substituting cheaper parts, "to save parts," which degrades quality and adds many variables, which complicates quality programs and product development itself.
Eliminating one of the worst counter-productive practices will then minimize variables that cause serious problems that range from quality to product development itself!, Too many change orders and variables slow ramps, and paradoxically raise quality costs. For a discussion on many quality costs, see the article on Cost of Quality at http://www.halfcostproducts.com/cost_of_quality.htm This summarizes a list of cost of quality categories published by the American Society of Quality.
The course section on DFM principles presents many design guidelines that optimize assembly and also improve quality by mistake-proofing the design. This is called Poka-yoke in Japanese and English classes that show how to design for Poka-Yoke are rare.
The leading-edge DFM section will also show how to do-it-right-the-first time, which will greatly reduce change-orders, which cost money, drain resources, add variables and have serious consequences. The course will also cite many leading companies, like Toyota, that says that late design changes are "expensive, suboptimal, and always degrade both product and process performance."
Another section correlates the cumulative effect of part count and quality statistically and encourages design simplification significantly reduces the number of parts and electrical connections. This is covered in the article on Designing for Quality which illustrates this with a graph that shows, for instance, that if a product has 500 parts that are all 99.9% good, then one third of the products will fail assuming perfect manufacturing
Design for Lean Production Platforms Families each of which can be Built On-Demand Without Inventory
This course is unique in showing how to concurrently engineer product families and flexible production cell equipment.
This course has a unique section on Design for Lean and Build-to-Order, which will make Lean Production easier to implement with much more effective results while making Build-to-Order practical with Spontaneous Supply Chains and eliminating forecasted inventory.
The class enables what makes Lean possible and successful, such
Ways to implement the most advanced product development:
NPD Champions and Task Forces
Hold a customized class for Champions or an Implementation Task force
Hold a customized class and workshop for a important project that will apply all the principles in a micro-climate or skunk-works.
Multi-functional Learning Team
The fastest way to implement the most advanced NPD system is to arrange a customized class for a multi-function team to immediate apply everything taught to a project where all the principles to apply to new projects microclimate as introduced in this course , which would be enhances if the project had its own project room fs
The official page of the Breakthrough Energy Coalition (led by the most famous high-tech leaders) is quoted as saying
Any research organization that has this problem, needs , first, Manufacturable Research, and, it that is not done, needs commercialization.
This is a unique set of methodologies that, for the first time, shows research labs many "low-hanging-fruit" cost savings that can easily be done in research efforts to ensure that whatever comes out of Research will result in manufacturable and scalable products. This is described in the article on Manufacturability Research,
Commercialize Innovation for Manufacturability
This is also a unique aspect of this Advanced NPD course. If research efforts have not done the above references "Manufacturable Research," then they will need to commercialize patents or acquired technologies or just proofs-of-principles that were designed without any thought of manufacturability. See article at on commercialization at http://www.halfcostproducts.com/commercialization.htm
copyright © 2019 by David M. Anderson
Book-length web-site on Half Cost Products: www.HalfCostProducts.com