Lean Product and Process Development (LPPD) is a multiple workshop, 40 to 60 hour series, used to re-engineer the entire product and process development progression.  AMT has helped clients such as ComauPICO streamline the entire process, and even use the new process as a business model, see www.comaupicoservices.com. AMT offers a proven method for team to quickly re-engineer multiple, linked, value stream/flow processes, and support organizations for lean operations.

A cross-functional LPPD team(s) defines the major value stream flow processes from customer, through design, tool build, pre-production, production, and final product delivery.  LPPD can get you organized to meet requirements for higher office productivity, APQP, and faster time-to-market.

LPPD teams are offered one of two powerful process mapping methods that AMT has streamlined for quick learning and use (teams start using the methods with one hour training). One is based on IDEF 0 (clink for more information on the IDEF method). 

LPPD teams collaborate in 10 to 12 one-half day workshops to:

1. Define Steps in Enterprise Process Flow
2. Define what needs to happen at each step, inputs, resources, outputs,
3. Next, the team develops needed training materials, new job descriptions, and start-up testing protocols.
4. Test a design or production job, make needed improvements, and prepare to start the new process(es).
5. Update ISO procedures and job descriptions.  Start up and improve the new system.

Eight (8) to twelve (12) knowledgeable team participants from manufacturing, engineering, production control, supply chain management, human resources, purchasing, and financial management comprise a successful lean enterprise team.

Workshop deliverables include a new value stream process definition that will reduce cost/waste, improve quality, and/or reduce time-to-market.  Training includes:

• Business process, input-output-resource-constraint analysis
• New business process implementation methods and Tooling
• Work instructions/check lists,
• Cost/benefit analysis, and
• Defining new or modified job positions.

Participants should have deep knowledge of the requirements of one or more of the steps in the enterprise value stream for the business unit. 

Projects normally require 40 Hours (ten, ½-day sessions) to 60 Hours (15, ½-day sessions) of the teams time.