Lean Designing Glenn Ballard TPS vs TPDS The

Lean Designing Glenn Ballard

TPS vs TPDS • The Toyota Production System (TPS) is a model for lean making. • The Toyota Product Development System (TPDS) is a model for lean designing.

Key Characteristics of the Toyota Product Development System • • • Set Based Concurrent Engineering Obeya Target Costing Knowledge-based Trade-Offs Chief Engineer

Set based concurrent engineering

Set Based Concurrent Engineering TPDS is famous for its ability to produce and study more design alternatives than competitors and still deliver product development projects faster, with lower cost, and with better quality.

How to explain this fact? • One possibility: less rework • That may account for time and cost, but why is quality better? • Possible answers: 1) Because it is easier to avoid defects than to remove them. 2) Because errors and defects tend to increase when doing work over again. 3) Because designs have been better shaped and selected for production.

Key Characteristics of the Toyota Product Development System • • • Set Based Concurrent Engineering Obeya Target Costing Knowledge-based Trade-Offs Chief Engineer

Courtesy of Stan Chiu, HGA

Key Characteristics of the Toyota Product Development System • • • Set Based Concurrent Engineering Obeya Target Costing Knowledge-based Trade-Offs Chief Engineer

Toyota designs to cost TPDS sets an allowable cost for products based on the net benefits in use to the producer over the life of that product. Note: Toyota is managing a portfolio of products, so the allowable cost may be based on expected benefits to the portfolio as a whole. Example: Filling a niche in model types.

Key Characteristics of the Toyota Product Development System • • • Set Based Concurrent Engineering Obeya Target Costing Knowledge-based Trade-Offs Chief Engineer

Trade-off Curves Eraci, et al. 2016. Knowledge Creation and Visualisation by Using Trade-off Curves to Enable Set-based Concurrent Engineering. Electronic Journal of Knowledge Management 14/1

Overall approach to using knowledge-based To. Cs within the SBCE process model

Key Characteristics of the Toyota Product Development System • • • Set Based Concurrent Engineering Obeya Target Costing Knowledge-based Trade-Offs Chief Engineer

Chief Engineer: Guardian of Customer Value Understanding what product features are valued by potential customers, and guiding the project to include those features in the product within project constraints.

Insert reference Suzuki’s YETs • Great high speed handling and stability • Fast and smooth ride • Super quiet • Elegant styling • Interior that feels warm and inviting • Great stability at high speed From Jeffrey Liker’s The Toyota Way YET • A pleasant ride • • Low fuel consumption Light weight Great aerodynamics Functional interior • Low aerodynamic friction

How these elements fit together • Organizational integration-physically creates the project ‘society’ • Knowledge-based trade-off curves enable set based engineering. • Clear targets, explicitly linked to project purpose • Leadership from experienced and respected chief engineer to focus (shared mission, clear targets) and energize the team—not only the project team, but also the functional departments; e. g. , powertrain engineering.

Questions about TPDS • What enables Chief Engineers to be effective in persuading others? • How is creativity promoted? • Is evaluation and selection from design alternatives in TPDS the same as Choosing by Advantages?

Rhetoric and Design ‘Rhetoric is design limited to words. Design is rhetoric unleashed. ’ Richard Buchanan (2001) Design and the new rhetoric: Productive arts in the philosophy of culture, in Philosophy and Rhetoric, Vol. 34, No. 3, pp. 183206.

Questions about TPDS • What enables Chief Engineers to be effective in persuading others? The three modes of persuasion: ethos, pathos and logos • How is creativity promoted? By identifying where creativity is needed. • Is evaluation and selection from design alternatives in TPDS the same as Choosing by Advantages? responsive to context; all stakeholders’ criteria are included; -facts before evaluation; -consensus sought.

Thank you for your attention. I look forward to hearing your questions and comments