Lean design

In the discussion about lean manufacturing, most of us have forgotten the processes happening prior to manufacturing. Identifying and analyzing customer requirement, identifying the marketing opportunities, conceptualizing and designing are some of the key things happening before manufacturing. Decisions made in these stages directly influence the value of the product, amount of waste it generates in manufacturing and even how it will perform in the market. Manufacturing process certainly adds value to the product so it is very important to be lean in manufacturing. But have you ever thought about lean designs and the value it can bring to your system.

Value addition to the product starts way before it reaches manufacturing. One of the most important phases in pre production value additions is the design phase. Design is undoubtedly controls most of the processes happening after. So needless to say that a good design can add huge amount of value to the product. It is important not only to make the designing process lean, it is also important to make the designs lean.

Designing process can take lots of time and effort and costs. This is one of the largest contributors to the concept to market time. Using concepts of lean like Just In Time, Mistake Proofing and Standardizing can help reduce the time and effort taken to develop a design.

When developing a product as a lean designer, the designer must make sure the product is not only fulfilling the customer and design aspects, but also it needs to be compatible with the lean processes. In design manufacturing constrains like equipment, processes and required skills must be considered. In simple terms a brilliant design will not work unless it can be manufactured with a reasonable cost and quality.

Some simple techniques might help designing products in a true lean way. Designing the full product as a set of standard components is one of key concepts. Although the vehicle’s outer design can be drastically different and innovative engines and gear boxes of an automobile will remain the same. So for the manufacturer there is no need to setup, test assemblies for these components separately. This approach to manufacturing will reduce the time required for manufacturing and related costs.

Ease of maintenance and ease of day to day use are very important aspects that need to be considered in designing a product. As much as users like the innovative new features and novelty, people like ease of handling and ease of maintenance. A product designed in a lean way will be very easy to use and also will be very easy to maintain.

Designing is a creative process. By mixing creative design capabilities with lean techniques and concepts can add greater value in the bigger picture. Ease of manufacturing, ease of use, ease of maintenance are among the direct benefits of lean designing apart from its obvious benefits like costs savings, lead time reduction and high quality of the end products.