Improving NPI
Effectiveness
using Lean Thinking
Webinar
6th October 2015
Everyone will be muted so that only the presenters will
be heard.
The presentation will be followed by a Q&A session.
Please type your question in the question box.
Recording will be made available after the webinar on
the Industry Forum website.
If you are experiencing any technical problems please
call us on 0121 717 6620.
Introduction
Presenters: Dave Durbin & Ian Ford
Industry Forum NPI Engineers
Topic: Improving New Product Introduction using
Lean Thinking
Typical NPI Process Effectiveness Results
Applying Lean thinking to NPI
NPI process structure and adherence
Enabling NPI process effectiveness
Audience Feedback
Is Lean applicable to NPI?
a) Yes, completely
b) Some Lean principles are relevant
c) No, not at all
d) Never used Lean
Are you normal?
NPI Assessment Results
Assessment scores show:
Average score vs own target = 51.3%
Average score vs World Class = 37.5%
Simplifying NPI
Process x People x Results = Effectiveness
Organisational Strategic
Capability Maturity
5 Training and coaching 5 Capability development
Bubble (success not
4 Ineffective process Effective and 4
Process Performance
necessarily World Class
Process Maturity
(variation in results) efficient process
sustainable)
3 Process 3 Strategy development
System development
Engine racing (doing
development
2 2 things right, but not
Chaotic process Inefficient process Struggling
doing the right
1 1 things)
1 2 3 4 5 1 4 9 16 25
Organisational Maturity Organisational Capability
Typical NPI improvement approach
Fixing leaks Repairing drains Mending door
Treating
timbers
What everyone sees in terms of the NPI process
What is the real situation?
Door damaged
Foundations are not solid!
Applying Lean to NPI
No structured
process
No structured process
Reliant on individuals
No standards to improve
Waste inherent in activity
Remember Transportation
Tim Wood Inventory
Motion
Waiting
Overproduction
Over-processing
Defects
7 Wastes
Can 5S and visual methods be
applied to NPI?
Process not
followed
Audience Feedback
How do you know if your NPI process is followed?
a) Dont check
b) Audit process adherence
c) Use results to judge adherence
d) Measure gate adherence
Process not followed
Not cross-functionally agreed
Conflicting priorities
Too complicated
No measurement
Poor senior level support
Process not as
effective as wed
like
Process not effective
Overprocessing
Strategy not linked to procedures
Measures not in place
Data available but no meaningful
analysis to drive improvement
Audience Feedback
How do you currently improve your NPI process?
a) No improvement occurs
b) Informal activity after an unsuccessful project
c) Informal activity after every project
d) A structured approach after every project
e) A structured approach continuously as lessons
are learned
How do we improve NPI?
5 Principles of Lean
1. Define Value
2. Map Value
Stream
3. Create Flow
4. Establish Pull
5. Pursue
Perfection
Advantages of applying Lean to
NPI
Reduced project leadtime
Competitive advantages
Customer confidence and ability to manage
customer
Standardising product modules design,
relating similar features to FMEA etc.
Conclusions
Remember the lean basics
Be data driven highlight and drive priority of
improvement opportunities
Set clear standards allow sharing of best practice
and inclusion of learning from experience
Organise the workplace (5S) ensure all tasks and
information are required and organised efficiently
Use visual management allow progress and status
to be seen by all stakeholders to prompt correct
reactions
Make work flow ensure all activities are completed
effectively and at the right time
For more information
www.industryforum.co.uk
www.industryforum.co.uk
