Design For Six Sigma, New Product Development, Product Development Process, Product Development Design, Lean Product Development

Lean Product Development

  • Capture the Potential of Lean Thinking

    Cost10% DiscountDigital Brochure
    Five-day program
    When you register five or more. Restrictions apply. Detailed information in a shareable format. download

    Learn essential strategies and key tools that will decrease time-to-market, reduce waste, streamline product development processes, enhance product quality, and fully integrate new product designs into a Lean production environment.

    This five-day program trains product development engineers and new product team members in Lean concepts, tools, and methods essential to the Toyota Product Development System (TPDS). Each day offers a set of learning objectives that enable participants to understand and appreciate the Lean product development process and its tools. Collectively, these objectives prepare participants to implement Lean development in their organization.

    Lean Product Development Program Components

    Overview of Lean Product Development

    • Introduction to the Toyota Product Development System: How It Works and Key Benefits
    • Problems with traditional product development
    • Overview of workflow within a lean product development system
    • The role of the customer, employees and organization
    • People systems: Client engineering and technical skill

    Traditional Lean Product Development Simulation

    • Illustrates typical wastes
    • Tracks metrics associated with traditional wastes

    The Lean Tools of Toyota Product Development System

    • Principles of Nemawashi
    • Principles of Ringi
    • Creating effective A3 reports for Lean Product Development
    • Hoshin management
    • Engineering Checklists

    Lean Value Stream Mapping for Lean Product Development

    • Introduction to value stream mapping
    • Mapping the current state
    • Lean product development principles
    • Mapping the future state
    • Creating an implementation plan

    Survey of Advanced Design Tools in a Lean Product Development System

    • Error proofing
    • Process for systematic error proofing
    • Definitions and applications

    Tools for Lean Launch and Implementation Planning

    • Introduction to the 3P Process
    • Lean Manufacturing Cell Design
    • Material Flow Planning
    • Lean Part Presentation

    Lean Product Development Simulation

    • Apply lean tools and techniques to the product development process
    • Track the metrics and realize the impact
  • Program Agenda

    Day One:

    • Introduction
    • Product Development Wastes
    • U of M Product Development Research
    • Engineering Simulation Round #1
    • Lean PD Processes
    • Lean PD Tools
      • Kentou Phase
      • Problem Solving
      • Set-Based Concurrent Engineering

    Day Two:

    • People Systems
      • Balance Functional Expertise with Cross-functional Integration
      • Develop Towering Technical Competence in All Engineers
      • Chief Engineer System
      • Supplier Partnerships
    • Lean PD Tools
      • Tools for Organizational Learning and Continuous Improvement
      • Tools for Communication and Alignment
    • Wrap-up

    Day Three:

    • Introduction
    • VSM Icons
    • Current State Map Building Blocks
    • Build a Current State Map
    • Current State Map Exercise
    • Identifying Waste in the Current State
    • Build Future State Map
    • Implementation

    Day Four:

    • Applying A3 Thinking and Problem Solving
    • Teach & Do with a Real Life Challenge You Are Facing at Work Today
      • Define the Problem - The Elements of a Good Problem Statement
      • Setting Clear Goals
      • Root Cause Analysis - Overview of Techniques
      • Countermeasures - Short and Long Term
      • Implementation Plan
      • Follow up - the critical "check" and "act/adjust" phase of PDCA
    • Case Study
      • Application of Lean PD at a Company That Previously Attended the Class
      • Q & A with Presenters

    Day Five:

    • Summary of Lean PD Principles
    • Simulation Round #2 - Lean
    • Leading the Change to Lean Product Development
  • Instructor

    John Drogosz

    John Drogosz

    Lean Specialist and Instructor
    Vice President for Lean Services, Optiprise, Inc.
    More About John...

  • Key Benefits

    • Learn about the Lean product development process and the tools of the Toyota Development System
    • Apply value stream mapping techniques to product and process development
    • Create an implementation plan for your organization
    • Develop systematic error proofing processes
    • Acquire tools for effectively launching your new product or process
    • Consider the roles of organizational culture and the challenges of leading lean change

    Program Fee

    $3,100* Covers the Five-Day Program

    Fee includes tuition, instructional materials, continental breakfast, lunch and a coffee break each day. Fee is payable in advance.* Upon registration, you will receive email confirmation including directions to the program site and recommended lodging.

    * Fee subject to change. Pricing not valid for onsite or custom programs.
    Please review our Professional Programs Payment and Cancellation Policy.


    A non-credit certificate of professional achievement in Lean Product Development from the University of Michigan College of Engineering will be awarded upon successfully completing the five-day program and passing an online exam.

    Materials and Resources

    A text is provided for this course. If you would like more information, click on the book below. This is for your information only. It is not necessary to buy your own book.

    The Toyota Product Development System: Integrating People, Process, and Technology

    In The Toyota Product Development System: Integrating People, Process, and Technology, James Morgan and Jeffrey Liker compare and contrast the world-class product development process of Toyota with that of a U.S. competitor. They use extensive examples from Toyota and the U.S. competitor to demonstrate value stream mapping as an extraordinarily powerful tool for continuous improvement.

    Through examples and case studies, this book illustrates specific techniques and proven practices for dealing with challenges associated with product development, such as synchronizing multiple disciplines, multiple function workload leveling, compound process variation, effective technology integration, and knowledge management. Readers of this book can focus on optimizing the entire product development value stream rather than focus on a specific tool or technology for local improvements.

Learn Lean Product Development


how to achieve results that will save time and money with methods, tools, and processes derived from years of research based at the University of Michigan.

See Lean Product Development


how it works through experience with a practical hands-on two-stage simulation that condenses the typical product development cycle.

Hear Lean Product Development


what happens when former students present a case study based on how they applied the techniques in their facility.