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Simulation Based Measuring the Benefits of Converting to Lean Product Design and Development: A Case Study of Manufacturing Sector of Pakistan

Sajid Muhammad, Wasim Ahmad, Hussain Salman, Jahanzaib Mirza

Advances in Science and Technology. Research Journal

2019

Vol. 13, no 1

128--137

Designers are facing the principal problems of effective decision making at the initial design stage of product development, which ultimately contribute to profit loss, low quality and increased time to launch the product onto the market. It requires a lot of knowledge and experience. Tools are required to analyze and ensure that crucial decisions have strong foundation before implementation. Discrete event simulation provides such a tool and has got potential to assist in decision making before final implementation. This research work aims measuring the benefits of transformation to lean product development (LPD) via simulation. Simulink-MATLAB tool was used for this purpose. The whole work is limited to design and cost estimation cells of a manufacturing company and consists of two phases. The first phase deals with the assessment of current working model of design and cost estimation cells. The areas for improvements were recognized at this phase. The proposed model for transformation to LPD was developed in the second phase. Four lean enablers namely product values, knowledge-based engineering, set-based concurrent engineering and poke-yoke were incorporated to further enhance the operation of the proposed model. This research work constitutes a useful case for practitioners. Keywords: decision making, discrete event simulation, lean product development, lean enablers

The combination of the Six Sigma and Design for Six Sigma workflow into an interactive process model for holistic improvement on product and process domain

Berg S.

Organizacja i Zarządzanie : kwartalnik naukowy

2011

nr 1

19-35

Six Sigma and Design for Six Sigma (DFSS) are both very successful strategies for the enhancement or the development of new products. Many researchers have studied Six Sigma and DFSS over the years and there is consensus that companies do benefit from applying both methodologies together. A clear understanding of when to use which approach is essential to optimize the potential of both methodologies. In general, the area of focus for projects is either on the process domain or on the product domain. By expanding the improvement scope of both domains, interactions of the Six Sigma and Design for Six Sigma methodology for improvement are possible and lead to enhanced process models for improvement, facilitating a holistic improvement approach. 102 implemented projects from Tenneco Inc.'s global engineering centers have been analyzed and grouped according to this model.

Six Sigma oraz Design for Six Sigma (DFSS) stanowią dwie bardzo skuteczne strategie wspomagania i rozwoju nowych produktów. Wielu badaczy, analizując przez lata Six Sigma oraz DFSS, doszło do wniosku, że przedsiębiorstwa czerpią korzyści ze stosowania obydwu metodologii jednocześnie. Klarowne rozumienie, kiedy należy wykorzystywać, które z tych podejść, jest kluczowe dla uzyskania optymalnego potencjału metod. Obszar projektów stanowią zarówno procesy, jak i produkty. Poprzez rozszerzenie zakresu poprawy obu tych dziedzin, możliwa staje się poprawa interakcji Six Sigma oraz Design fo Six Sigma, co prowadzi do stworzenia lepszych modeli uwzględniających podejście charakteryzujące poprawę w rozumieniu całościowym. Według modelu zaprezentowanego w niniejszym artykule przeanalizowano i pogrupowano 102 projekty wdrożone w globalnych centrach firmy Tenneco Inc.