Beyond theory: An examination of lean new product introduction practices in the UK

Interest is growing around the application of lean techniques to new product introduction (NPI). Although a relatively emergent topic compared with the application of 'lean' within the factory, since 2000 there has been an exponential rise in the literature on this subject. However, much of this work focuses on describing and extolling the virtues of the 'Toyota approach' to design. Therefore, by way of a stock take for the UK, the present authors' research has set out to understand how well lean product design practices have been adopted by leading manufacturers. This has been achieved by carrying out in-depth case studies with three carefully selected manufacturers of complex engineered products. This paper describes these studies, the detailed results and subsequent findings, and concludes that both the awareness and adoption of practices is generally embryonic and far removed from the theory advocated in the literature. © IMechE 2007.

Industrialization as a key element of sustainable product-service solutions

Product-service systems are seen by many authors to offer potential for significant sustainability benefit. Manufacturing companies are said to be essential to such a change through their influence over product performance and over the use and end-of-life stages. Yet linking these stages such that the producer is incentivized to improve the performance of later stages is still a challenge. This paper argues for placing the producer at the centre of a new arrangement: by seeking to utilize the producer's knowledge of designing and the knowledge of volume production, through creation of platforms, while cooperating closely with other actors. The paper describes three case studies that have used such an approach to design and implement new food production systems. Based on 12 months of action research observations, 10 participating organizations from the cases were studied, and the implemented solutions assessed for environmental, economic and social performance. The results demonstrate a high level of sustainability benefit is achievable using platforms and partners to design product-service systems, while highlighting that changes to production arrangements are necessary but not sufficient to improve whole life-cycle environmental performance of product-service systems, and that producers need to cooperate closely with other actors to achieve the claimed benefits.

Environmental priorities in strategic product development

This paper reports some results from a major research project on the integration of environmental issues into design in the electrical and electronic industry. Product development practice and ecodesign methods were examined along with qualitative data from 19 manufacturers, using interviews and an action research methodology. A four-stage framework for ecodesign practice resulted: first, to make an environmental assessment from a life cycle viewpoint; then to communicate the analysis and collect feedback; thirdly to prioritize the environmental issues and finally to complete the design using relevant tools and methods. This 'ARPI' framework (analyse, report, prioritize, improve) applies to both strategic and operational levels. Initial testing of the framework in collaborating companies highlighted difficulties with communication with design teams; the role of 'ecodesign champions' is explained. Other challenges are the development of customized tools and the training of designers. The study concludes that the prioritization step is critical, as it simplifies and clarifies the tasks in design that take place after formulation of the specification. Copyright (C) 2000 John Wiley and Sons, Ltd. and ERP Environment.

Strategies for product recovery decisions

Product recovery is beset by uncertainty regarding the quality of end-of-life (EOL) products, and in order to ascertain the reusability of these products, they have to undergo expensive tests. This undermines the profitability of the recovery process. The key to improve the effectiveness of product recovery is to improve the quality of information available before testing. Emerging data capture technologies can significantly improve the availability of information. However, in order to maximise the potential of these technologies, appropriate decision-making algorithms that exploit such information must be developed. We model the recovery process using a decision-theoretic approach, and derive strategies to ascertain the reusability of EOL products, and also to decide when tests are beneficial. We show that improving the quality of information leads to increase in effectiveness of the recovery process by reducing the need for tests. Copyright © 2009 Inderscience Enterprises Ltd.

The intelligent product driven supply chain

Establishing connectivity of products with real-time information about themselves can at one level provide accurate data, and at another, allow products to assess and influence their own destiny. In this way, the specification for an intelligent product is being built - one whose information content is permanently bound to its material content. This paper explores the impact of such development on supply chains, contrasting between simple and complex product supply chains. The Auto-ID project is on track to enable such connectivity between products and information using a single, open-standard, data repository for storage and retrieval of product information. The potential impact on the design and management of supply chains is immense. This paper provides an introduction to of some of these changes, demonstrating that by enabling intelligent products, Auto ID systems will be instrumental in driving future supply chains. The paper also identifies specific application areas for this technology in the product supply chain.

A starting point for addressing product innovativeness in the Fuzzy Front-End

Product innovativeness is a primary contingent factor to be addressed for the development of flexible management for the front-end. However, due to complexity of this early phase of the innovation process, the definition of which attributes to customise is critical to support a contingent approach. Therefore, this study investigates front-end attributes that need to be customised to permit effective management for different degrees of innovation. To accomplish this aim, a literature review and five case studies were performed. The findings highlighted the front-end strategic and operational levels as factors influencing the front-end attributes related to product innovativeness. In conclusion, this study suggests that two front-end attributes should be customised: development activities and decision-making approach. Copyright © 2011 Inderscience Enterprises Ltd.

A framework for designing product service systems

In this competitive globalizing scenario, manufacturers are adopting a strategy of bundling products and services into an integrated solution to create sustainable competitive advantage. Servitizing manufacturers are increasingly transforming their processes and practices to build product-service systems (PSS). During this transformation they require substantial support to face stringent challenges. Research in the PSS domain is heading towards the development of a design theory and methodology that facilitates the systematic creation of viable PSS conceptual designs. In this paper, various proposed design methods are reviewed and research gaps are summarized. Primarily, it has been observed that the importance of the capabilities of the stakeholders involved in designing PSS has not been noted in the proposed methods. Regarding this capability view point, a framework for designing PSS has been proposed. This framework highlights the important features required in designing PSS such as co-creation, responsibilities and competences. Every step in the framework has been explained with a case study involving laser systems used for manufacturing cutting operation.

Opt-out options in new product co-development partnerships

We study three contractual arrangements—co-development, licensing, and co-development with opt-out options—for the joint development of new products between a small and financially constrained innovator firm and a large technology company, as in the case of a biotech innovator and a major pharma company. We formulate our arguments in the context of a two-stage model, characterized by technical risk and stochastically changing cost and revenue projections. The model captures the main disadvantages of traditional co-development and licensing arrangements: in co-development the small firm runs a risk of running out of capital as future costs rise, while licensing for milestone and royalty (M&R) payments, which eliminates the latter risk, introduces inefficiency, as profitable projects might be abandoned. Counter to intuition we show that the biotech's payoff in a licensing contract is not monotonically increasing in the M&R terms. We also show that an option clause in a co-development contract that gives the small firm the right but not the obligation to opt out of co-development and into a pre-agreed licensing arrangement avoids the problems associated with fully committed co-development or licensing: the probability that the small firm will run out of capital is greatly reduced or completely eliminated and profitable projects are never abandoned.

An optimal design process for an adequate product?

The 'optimal' or 'best' design process may be the shortest or cheapest process, or the one that leads to a particularly desirable product, or to a reliable and maintainable product, or to a manufacturable product, or some combination of all of these. It is likely to satisfy the aspirations of the organisation to invest an appropriate amount of resource in the development of a specific new market opportunity, set in the context of longer-term business goals. This paper describes the progress made in over ten years of research on process modelling undertaken at the Cambridge Engineering Design Centre to identify an 'optimal' design process with which to develop an 'adequate' product.