A systematic method for leaning engineering processes

For the past decade, lean manufacturing has reshaped manufacturing processes at numerous corporations. The foundation of lean manufacturing is the elimination of waste. There are three important value streams in the realization of any, product---the engineering value stream, the manufacturing value stream, and the information management value stream.{09}This research focuses on the engineering value stream.; This research presents a basic methodology for waste elimination in engineering as well as the basic tools that will serve as a starting point for the lean journey. Manufacturing equipment installation---a manufacturing engineering process--is used as an example to demonstrate the elimination of waste in engineering.; To support this research on waste and variability, various equipment procurement practices adopted by major automakers across the globe were benchmarked. Equipment installation is a sub-process in the equipment procurement process. The equipment procurement process begins at manufacturing equipment order placement and ends with the qualification of manufacturing equipment in the plants. Findings from this study rank Toyota as the most efficient automaker in equipment procurement. This research also describes specific practices adopted by Toyota that enable Toyota to beat the competitors on quality, cost, and delivery metrics. A comparison of specific practices adopted by other automakers is also made.; Findings from the benchmarking and the variability study help design a common equipment installation process that not only eliminates the identified wastes, but also is applicable across the entire manufacturing enterprise. Lean manufacturing tools such as VSM, operator balance chart, operator work combination chart, single minute exchange of die, and visual control and management are successfully mapped and validated for use in engineering applications.; The systematic method followed in this research to improve the manufacturing equipment installation process is generalized for application to other engineering processes in the form of a 10-step method. This generalized systematic, 10-step method for engineering waste elimination and process improvement will help engineering organizations systematically identify, measure, and eliminate engineering wastes from all other engineering processes.; In today's competitive world, the ability to bring better products to market faster has become the focal point of competition. The systematic method for waste elimination proposed in this research will enable engineering organizations to systematically identify, measure, and eliminate waste and bring about drastic improvements in engineering process performance. The use of this systematic method for engineering waste elimination holds significant promise for organizations wanting to outperform their competitors on quality, cost, and delivery. (Abstract shortened by UMI.)...