Skip to navigation, content

Second Generation Lean Product Development: Applying the Principles of Flow

Previously called "Achieving Lean Product Development"

Date: November 17 - 18, 2009

Location: Chicago, IL

Learn the lean techniques that can provide a quick and lasting return on investment for product development at this highly rated workshop led by noted expert Don Reinertsen

N.B. This workshop was originally offered under the name, "Achieving Lean Product Development."  The name has been updated to reflect the many changes that have been made to the course curriculum since the workshop's inception.  Please read a special note from Don Reinertsen about the most recent updates to this workshop and whether or not this warrants repeat attendance by previous participants.  CLICK HERE

WHY CONSIDER LEAN PRODUCT DEVELOPMENT?

Lean methods have been used for over 50 years in production processes, producing huge economic benefits. They are based on principles that are transferable to product development. In fact, these methods are the only practical way to simultaneously achieve large improvements in the speed, quality, and cost of product development. However, using lean methods in product development requires some insight. To succeed we must have a clear idea of which management practices obstruct flow, and how to remove these obstructions. Without this insight we will dilute our energy in lengthy process mapping exercises, and ultimately lose momentum. This workshop focuses on proven leverage points. It concentrates on specific practical methods that have helped participants achieve as much as a 90 percent reduction in cycle time. It uses a unique economic approach to identify which methods will provide the fastest payback and teaches you the science behind the methods. This seminar is fundamentally different from other workshops in its intense focus on quantification and economic justification. It provides practical methods rather than general philosophical principles.

Note: This course is limited to 35 participants -- early registration is highly recommended.

Principles of Product Development Flow

 

SPECIAL BOOK BONUS

Attendees will receive one free copy of Don Reinertsen's latest book, The Principles of Product Development Flow. For more info click here.
 

PARTICIPATION RESTRICTION:

Due to limited space, this workshop is offered exclusively to industry practitioners. Sorry, but registration applications will not be accepted from academics or consultants.

 

 

 

Workshop Instructor

Don ReinertsenDon Reinertsen, author of The Principles of Product Development Flow: Second Generation Lean Product Development

DON REINERTSEN is President of Reinertsen & Associates and author of the new book, The Principles of Product Development Flow: Second Generation Lean Product Development. He specializes in the management of product development processes. Before forming his own firm, he consulted at McKinsey & Co., an international management consulting firm, and was Senior Vice President of Operations at Zimmerman Holdings, a private diversified manufacturing company. For 30 years he has been bringing fresh perspectives and quantitative rigor to development process management.

In 1983, while a consultant at McKinsey & Co., he wrote a landmark article in Electronic Business magazine that first quantified the value of development speed. This article has been cited in the frequently quoted McKinsey study that indicated “6 months delay can be worth 33 percent of lifecycle profits.” He coined the term “Fuzzy Front End” in 1983 and began applying world class manufacturing techniques in product development in 1985. In 1997, his landmark book, Managing the Design Factory, first introduced the ideas that have become known as Lean Product Development. Don is co-author of the best-sellng book, Developing Products in Half the Time. He holds a B.S. in Electrical Engineering from Cornell University and an M.B.A. with distinction from Harvard Business School.

Through exercises, lectures and facilitated Q&A, you will learn how to:

 

  • identify when queues cause economic damage
  • use batch size reduction and WIP constraints to improve flow
  • create fast feedback loops to increase quality and efficiency
  • reduce the economic cost of variability without stifling innovation
  • develop a step-by-step implementation plan to incorporate lean principles into your own development process

Course Outline

Through experiential exercises, lectures and facilitated Q&A, you will learn how to:

  • identify when queues cause economic damage
  • use batch size reduction and WIP constraints to improve flow
  • create fast feedback loops to increase quality and efficiency
  • reduce the economic cost of variability without stifling innovation
  • develop a step-by-step implementation plan to incorporate lean principles into your own development process

I - Introduction
II - Establishing an Economic Framework
III - Managing Queues
IV - Exploiting Variability
V - Reducing Batch Size
VI - Applying WIP Constraints
VII -
Controlling Flow 1: Congestion & Cadence
VIII - Controlling Flow 2: Synchronization & Sequencing
IX - Accelerating Feedback
X - Decentralizing Control
XI - Finding Waste
XII - Implementation

Limited to 35 participants - Register Today!

--------------------------------------------------------------------------------

I. Introduction

Most companies that applying lean methods in product development fail to appreciate the critical differences between repetitive manufacturing processes and non-repetitive development processes. Such differences mean that waste is found in very different places. Until this is recognized, companies will only attack easily visible, but superficial forms of waste.

This section will cover:

  • An overview of how lean techniques improve product development speed, quality, and cost
  • An understanding of the critical differences between product development and manufacturing
  • An explanation of importance of Design-in-Process Inventory


--------------------------------------------------------------------------------

II. Establishing an Economic Framework

Every product development process has multiple economic goals. To balance these goals we must express them in the same unit of measure. This method allows us to quantify the Cost of Delay and to use it to determine the economic cost of queues in our process.

This section will cover:

  • How to quantify the Cost of Delay
  • How to use information to improve decision-making


--------------------------------------------------------------------------------

III. Managing Queues

Variability is a greatly misunderstood concept in product development. Paradoxically, you cannot add value in product development without adding variability, but you can add variability without adding value. A product must be changed to add value, and this change creates uncertainty. This section will cover:

Key Learnings

  • How queues affect economic performance
  • How variability and over-utilization cause queues
  • How to measure and manage queues
  • The 10 most important product development queues


--------------------------------------------------------------------------------

IV. Exploiting Variability

Variability is a greatly misunderstood concept in product development. Paradoxically, you cannot add value in product development without adding variability, but you can add variability without adding value. A product must be changed to add value, and this change creates uncertainty.

This section will cover:

  • How to distinguish between good and bad variability
  • How to eliminate unnecessary variability
  • How to reduce the economic consequences of necessary variability


--------------------------------------------------------------------------------

V. Reducing Batch Size

In manufacturing, batch size reduction is the key factor that creates order of magnitude reductions in cycle time. In product development, only 3 percent of companies have formal efforts to reduce development process batch size.

This section will cover:

  • The importance of small batch size and how to achieve it
  • How to recognize the ten most common batch size problems in product development


--------------------------------------------------------------------------------

VI. Applying WIP Constraints

Most product development processes neither measure nor control WIP. Yet, excessive WIP leads to long cycle time and slow feedback loops. Effective WIP management requires knowing when WIP is excessive, and having tools to correct this problem.

This section will cover:

  • The science and economics of WIP constraints
  • Nine practical ways to react to WIP explosions


--------------------------------------------------------------------------------

VII. Controlling Flow 1: Congestion & Cadence

Processes with variability, such as product development, are prone to congestion. Both traffic systems and telecommunication systems provide valuable insights on congestion avoidance and congestion control. Today’s development processes underutilize cadence.

This section will cover:

  • What causes congestion and how we can prevent it
  • How a regular cadence improves performance
  • Examples of cadence applied to product development


--------------------------------------------------------------------------------

VIII. Controlling Flow 2: Synchronization & Sequencing

Synchronization reduces the formation of queues. When queues form we can reduce their cost by sequencing work correctly. The First-in First-out methods of manufacturing are poorly suited to this challenge. Fortunately, product developers can exploit more advanced approaches that are used in computer operating systems.

This section will cover:

  • How synchronization reduces queues
  • Economically-based methods for sequencing work
  • A network-based approach for managing flow


--------------------------------------------------------------------------------

IX. Accelerating Feedback

Slow feedback loops cause enormous waste in product development. Yet, many developers do not measure feedback speed or try to improve it. Well-structured feedback loops actually create spectacular opportunities to smooth flow, increase efficiency, and improve quality.

This section will cover:

  • Why fast feedback is critical
  • How feedback reduces variability and improves flow
  • Metrics for managing flow-based product development


--------------------------------------------------------------------------------

X. Decentralizing Control

Some product developers see highly centralized control as the only way to improve performance; others argue for complete decentralization. We will examine the lessons that can be learned from military approaches that balance centralization and decentralization.

This section will cover:

  • The advantages and disadvantages of decentralized control
  • How to preserve alignment without sacrificing initiative


--------------------------------------------------------------------------------

XI. Finding Waste

Because product development processes add value in different ways than manufacturing processes, waste is found in different places. Typically, waste shows up in predictable places in development processes.

This section will cover:

  • Ten common areas of product development waste

 --------------------------------------------------------------------------------

XII. Implementation

The final section will review factors that are likely to lead to successful implementation. Course participants will begin designing a plan for implementation. This section will cover:

This section will cover:

  • How to initiate pilot programs and scale them up
  • A group exercise to identify immediate next steps

Who Should Attend:

This program is designed for managers who currently play an important role in product development. It will be particularly useful to companies that are reaching the point of diminishing returns using conventional approaches to product development and to those who wish to quickly get benefits using lean methods. It is preferred that participants have a basic understanding of lean techniques and at least 5 years of experience in product development. Attendees should bring a calculator, since the course will involve some light calculations. The techniques covered are general methods of analysis rather than industry specific rules. Just as physics applies to both large objects and small ones, the methods used in this course can be applied in a wide variety of industries.

This course is also available as an onsite workshop To request a proposal for an in-house workshop, please contact Tracey Kimball via email at tracey@roundtable.com or by phone at 781-891-8080 ext. 214

PARTICIPATION RESTRICTION:  Due to limited space, this workshop is offered exclusively to industry practitioners. Sorry, but registration applications will not be accepted from academics or consultants.

IF YOU HAVE ATTENDED THIS COURSE PREVIOUSLY...You may be wondering if the updates to this course warrant your repeat attendance. Some of you may find it to be a great refresher that will reenergize your efforts and others will experience much easier implementation if they attend again with team members to experience the course alongside them. If you are unsure that there is enough new value for yourself in the course restructuring, you can speak directly with Don Reinertsen by phoning him at your convenience at 310-373-5332.

A special note from Don Reinertsen about recent updates to this workshop:

Dear Colleague,

In November, 2009 we will take a major step forward in our best-selling seminar, Achieving Lean Product Development. For the past six years, we have been progressively adding ideas that go beyond the methods of Lean Manufacturing. Quite frankly, the methods of manufacturing are optimized for repetitive activities with low-variability; they must be enhanced to deal with the unpredictable, non-homogeneous flows that we confront in product development.

Fortunately, we have a rich pool of alternative methods in telecommunication network design, computer operating systems, and traffic flow theory. These ideas are science-based, practical, and proven to work. Most importantly, they enable us to achieve flow in the presence of high variability, the fundamental problem product developers must solve. You see, without variability there can be no innovation, and without innovation there can be no value-added. Lean Product Development has the potential to go far beyond copying the way Toyota develops automobiles. That is why we call this approach "Second Generation Lean Product Development."

For the last six years we have been limited by the fact that the companion book for the seminar, Managing the Design Factory, was written 13 years ago, back when Bill Clinton was President, 5 years before the first ipod. We held back certain advanced ideas because attendees had no reference to turn to after the course. This problem has been solved. We now have a brand new book, The Principles of Product Development Flow: Second Generation Lean Product Development. With it we can move as fast as we like.

This has enabled us to reorganize the seminar. We have preserved what has made it so popular: practical methods, solid science, and economically-grounded decision-making. Such methods produce results, enabling course attendees to achieve 5-10x improvements in key areas of their development process.

You'll get plenty of content as we cover approaches including batch size reduction, cadence, WIP constraints, and flow control. In addition, you'll have a great opportunity to interact with other managers that are at the leading edge of this exciting new field. Please take a quick look at the seminar description and some of the comments of past attendees.

Feel free to call me at 310-373-5332 if you have any questions. I'd be glad to explain what I think is unique about this seminar. I hope you can join me for our next offering of our top rated two-day workshop, now called Second Generation Lean Product Development.

Sincerely,

Don Reinertsen
 

Customer Testimonials

Here's what previous workshop attendees had to say about Achieving Lean Product Development:

"Don is a dynamic and influential resource who effortlessly transfers knowledge, leverages experience and provides clarity to typical product development pitfalls. He has a knack of challenging existing paradigms and offering more insightful approaches to enable excellence. Your eye-opening experience is a seminar away."

Chris Bardeggia
Director of Engineering
Global Robust Product Design
Whirlpool Corporation

"This workshop outlays the true lean ways to improve any product development path with clear and measurable techniques."

Tim Acevedo
Group Leader
Engineering Product Innovation
Biolab, Inc.

"Great seminar and presentation. "real life" examples provided great clarification. I am convinced that lean method can be implemented with ease and success. Instructor is well versed and presents material in an understandable and easy communicative manner."

Cindy Bracht
Door Team Leader
Marvin Windows & Doors

"One of the most useful seminars I have attended."

Steve Milz
VP, Engineering
Lincoln Food Service

"thought provoking economic basis for decisions, queue analysis - things I hadn't really considered prior to this course"

Mark Lazar
Manager, Electrical Engineering
Badger Meter, Inc.

"Two very good take-aways are:

stage gate PDP is flawed in implementation - we will have to rewrite our process
usefulness of the cost of delay calculation.
Also, lots of good reinforcement for small batch sizes"

Harold Devisser
Engineering Manager
Husky Injection Molding

“I was very encouraged to have rigor and benefit #’s associated with “common sense,” which is often opposed to required work processes and approaches. Using analytical tools will help me form and articulate recommendations that will be believed and have positive business impact.”

Jeff Coult
Sr. Manager, Engineering
Honeywell

"Many of the concepts and tools address issues and frustrations that I have experienced in product development. I am energized to bring them to my work."

Greg Williams
Group Manager R&D
Dade Behring

"Excellent session! Excellent instructor! Very informative...The course does an excellent job applying lean principles and methods to product development process."

John Manson
Engineering Manager
Kimball International

"Instructor extremely knowledgeable and insightful across a wide range of industries."

Jim Holt
Manager of Systems Engineering
United Defense

"This workshop was very valuable. We're going home with lots of ideas in how to approach improving our R&D organization. The idea of taking small steps to improve a piece of the process quickly is a good approach."

Ken Peterson
Product Development Director
Medtronic Physio-Control

"Good solid focus on product development - introduced new concepts and also served to reinforce core ideas from his product development books and tied it all together nicely. Very practical, experience-based information"

Dave Skerkoski
Development Manager
Keithley Instruments, Inc.

"The commonality and desire to successfully implement new projects are gathered in one room. This gathering of various companies sharing common issues is comforting. We don't feel like we're on this deserted island alone."

Jeffrey Ogi
IPD Lead
Parker Hannifin

"A secondary benefit is the side discussions during meals and breaks. The group consists of people dealing with similar issues. Hearing how they dealt with items and discussing their needs was very helpful."

Randy Horning
Hardware Design Manager
LSI Logic

"Best linkage I've seen of LEAN techniques /terminology to design/development activities."

Kathy Mullen
Design Quality Lead
United Defense

"Very useful, especially since it was a smaller, more intimate group. Content was exceptional and applies to so many and varied industries...Don is an excellent speaker in keeping all participants involved and engaged."

Lisa Ottoson
AVP, Director Product Development
Federal Home Loan Bank

"Great points about how to apply lean to R&D, especially around the information flow applications...Good illustration of the differences between manufacturing and R&D."

Alistair Norval
KOS Director
Eastman Kodak

"Excellent presentation of the key differences between lean in manufacturing and in New Product Development."

John Trainor
Director, Program Management
Duracell

"This was a great discussion and I learned a lot about lean development and process technique. The information that I obtained will be an asset for my company as we evolve our PD/PM processes."

Richard Obiso
Senior Scientist, Project Analyst
Digene
 

Note: This course is limited to 35 participants -- early registration is highly recommended.

Participation Restriction: Due to limited space, this workshop is offered exclusively to industry practitioners. Sorry, but registration applications will not be accepted from academics or consultants.

Fee: $1995/person

Fee includes program materials, luncheons, continental breakfasts, refreshment breaks and complimentary copy of Product Development Flow.

Workshop Schedule:
Two-Day workshop format. The workshop will be held November 17-18, 2009

Day One:
Registration /continental breakfast: 7:30-8:30am
Session begins at 8:30am and concludes at 5:00pm
Networking Reception: 5:00-6:30pm

Day Two:
Continental breakfast: 7:00-8:00am
Session begins at 8:00am and concludes at 4:30pm

Location & Hotel Accommodations:

The session will be held at the

Hyatt Regency O'Hare
9300 W. Bryn Mawr avenue
Rosemont 60018

The special room rate is $199. Call 847-696-1234 or 800-233-1234 for reservations. Be sure to mention Management Roundtable's Lean Product Development workshop to receive the preferred rate.

Cancellations/Substitutions:

You may send a substitute attendee in your place at any time with no penalty (please inform us in advance, if possible). Cancellations made within 5 business days are subject to a $500 administration fee or the full fee can be credited towards a future purchase. No-shows are liable for the full fee.

Workshop Attire:

We recommend attire in the category of "business casual". It is highly encouraged that you also dress is layers when possible to remain comfortable—please be aware that event facilities are notorious for temperature fluctuations throughout the day of the event.
 

Workshop brochure

Download workshop brochure

How to register

Register for this event:

Or register by phone:

Call 1-800-338-2223 or 781-891-8080 (9:00am - 5:30pm EST)

In company training

This session can be brought directly to your site. Benefits include:

  • Lower cost per participant
  • Time savings
  • No travel required
  • Content tailored to your specific needs
  • Implementation is jump-started through team participation and instructor's hands-on guidance

Contact 781-891-8080 for more information and price quote.