The Lean-Based DMAIC Methodology for Optimization of Product Development Process (PDP)

Abstract

The current market scenario is that every company/customer wants to produce/buy best in class products at record cost and time without compromising quality. As a result, every business setup closely monitors and controls three major parameters named time, cost, and quality. If any organization optimizes all three mentioned, then it can gain a competitive advantage. Many companies that “Make-to-Order” have longer lead-time and time required to design and develop the product is the crucial reason behind it. So, companies want to minimize that time as much as possible and this can be achieved with the lean approach, which focuses on eliminating waste in product development. The article proposes a lean-based DMAIC methodology, which has been tested and verified in one of India’s automotive part supplier companies. The proposed methodology helped in identifying the problems and helped to address problems by actions or solutions that can be implemented.KeywordsLeanLean DevelopmentProduct Development Process (PDP)DMAICValue Stream Mapping (VSM)Ishikawa Diagram