Lean Applications & Deployment In Product Development At DPH Co.,Ltd.

In 1990,the researchers of the MIT International Motor Vehicle Program (IMVP)published The Machine that Changed the World:The Story of Lean Production.1 John Krafcik coined the term "Lean Production" to describe an approach that used less of everything and eliminate all the non value added waste in the production,to get the maximum productivity by minimum input.China has become the 'spot light' in world economy develpment for years of strong fast growing.By the attraction of the huge market interests,quite a lot world famous enterprise coming into China market to get advange of the opportunities,especially in the Auto industry.Key OEMs like GM,FORD, BENZ,BMW,TOYOTA,HONDA,HYUNDAI,PEUGEOT set a production or R&D base in China,while this also boost the footprint re-organization for Auto parts suppliers,a fiece competition roll out for the region.DPH is a world leading global supplier of automotive systems,including 6 divisions as:Electronics and Safety System,Electrical System,E&C Powertrain System,THERMAL Systems,and Product & Service Solutions.it nearly covers the major field for Auto parts,and provide a whole package for products and solution.The Japan's Auto manufacturers are not able to compete against the American opponents in the same operation model during the prosperouse industry time.Even after dozen years of production,the total volume of Tovota can not reach to the half of one day's production in Ford.At meanwhile.Japan's company were confronting less investiment and technology,it's even harder for them to reach to the scale of mass production in the situation after the world war.DPH lean practices is based on Toyota production system,with consideration the feature and culture specifically for DPH,we set up our own manufacturing system which called OS.Characterized in three area:Svstematic:Develop a system that combine all the process and support tool,optimize the whole process from the receiving area-supermarket-production-delivery.Standardization:Set up a standardized process to minimize the variance to improve the efficiency and quality.Care and execute in detailsDive into the every details in dioganosis and execution,it will help clear any obstacles during the future implementation phase.It will be a bottleneck when the operation system in manufacturing developed to a certain phase,and it can also be easily copied by others in the method.For keeping the advantage over the counter partners,it becomes imperative to make proper strategy on the innovation of product technology and management system.This include a clear plan for the product portfolio in long and short term,feasibiblity study,competitiveness analysis study in the product life time,system tool,and development resources building.In China,the product development management originated from the 'planning economy' structure,and transferred to market driven structure from 90's,this bring a big challenge to the product innovation,fast response for enterprise. Fierce competitive conditions are driving companies to adopt Lean strategies to improve corporate financial performance.Eliminating risk inexecution as new products are brought to market to fuel growth is an imperative to achieving success.Lean strategies are increasingly being extended to include groups outside of operations;most notably product development.To date,very few companies have successfully,for some of the specific feature on Research and Development,there are still not so much well-shaped theory and practices.Most of the case is,engineering got the lean philosophy and tool training course,but that's it,no further clear strategy and plan.With lean successfully being implemented in DPH production,it's effectiveness was recognized by top management team,they have confidence to deploy the lean thoughts in all functions.Hence,product development and management is payed an extremely attention.We need a solid and fast response system to customer requirements facing the fiece competition,the system is called EOS by DPHEnterprise Product Lifecycle Management(PLM)software that combines business processes like phase-based new product program management as well as document,file,and data control plays an essential role in enabling Lean in product development.Lean is a concept based on fundamental principlesValue is defined by the customer-Value Stream identifiedAll waste is eliminated-Value stream has been refined so that only value added steps remainProduct flows through the manufacturing system-Single piece flow is the ultimate stateProduction matches the customer "pull" rate-Material is pulled through the entire systemContinuous 'Pursuit of Perfection'No 'defect forward' cultureDo not pass a defect to next step,including missing information.StopcultureDo not start next process if missing inputs.Escalate,assess risk and determine if proceeding is feasible.'Fix Quick' culture -Immediate feedback and resolution of source of QVC issues.'Visual'culture -Use simple visual controls for managing processes.Counter-measures:Set up a standard design data base gradually,to esnsure the common standardized components being selected at the start of the design, in order to reduce the variety and complexity on parts.Optimize the supply chain by working together with Purchasing Department.Finding out the linkage between all the functional departments,who gives the input and output to each other,and then set up the connectivity among all the swimlanes,ensure the information goes fluently during the perspective pipes and being the most efficient way from an overall view on the operations.