Lean Product Development Process with Design Verification Stages in the Value Stream of Automotive Industry

In the automotive industry, lean projects and innovation creation come to life by being updated under the control of systematic interdisciplinary process flows. The lean product development process that changes the shell, defined under the light of the variables created by the competitive conditions, is today measured by the value flow efficiency and the global market spread of the final product. Consequently, the lean product development approach, which aims to identify and purify all the wastes that do none value or create value to the system or cause burdens in the new product development process, is shaped by step-by-step approvals in the flow. In the main automotive industry company practices within the scope of the research (3 national, 3 international), the beginning of the concept of lean in design is to define and optimize the steps in the product development process under the value stream map. Therefore, the product function for which the customer has paid for, the function of the new product or the physical structure used to meet the needs in question, the comfort, life, experience, innovations of the scope that constitute the new product concept are planned and verified and implemented in the simplified automotive design stages at the beginning of the lean product development process. In this research, initial automotive design objectives and stages are at the focal point of the innovation and added value creation brought by the concept of “lean” approach. The research is modelled on the determination of steps that do not create added value together with the points where the flow circuits’ or stems, the process is devalued, the interdisciplinary holistic studies intensify, the information and delay begin and end in the sequential and simultaneous design validation step transition stages, which are examined under the lean approach. As a visual and virtual tool that enables the elaboration of nominal values such as the total duration of the design verification stages and the influence of interdisciplinary stakeholders or the test level of the product design with the new product added, it reveals the value flow or losses. Hence research;from innovation creation and new product design steps, which constitute the initial stages of the lean product development process, to design verification analysis, the efficiency of the automotive company processes within the scope of the research has been measured by comparing using lean automotive design techniques, methods and concepts.

Evaluation of Lean Product Development Stages of Autonomous Vehicle Technologies with AHP Method

The potential innovation and emerging workforce created by autonomous vehicle technologies, which have just entered the lean product development disciplines, play an important role in the development or change of the automotive manufacturing industry. Therefore, the intensity of work and the innovation practices brought by the technologies in question at each step of very different and interdisciplinary studies deeply affect the new and lean product development steps. Comparatively measuring the operating weight of new autonomous vehicle technologies in different company structures in these lean product development steps has important consequences for the development and change of the automotive industry under heavy global competition. On the other hand, it is difficult to measure the innovation input or the use of new autonomous technology under the AHP mathematical model of each part that constitutes the whole of the lean product development process, but it also creates the future predictions of the sector. The Analytical Hierarchy Process (AHP), which is one of the multi-purpose decision-making methods, was used to determine the most intense value creation, the design and development phase where there is innovation input, or the lean product development discipline throughout the whole process. The AHP method was preferred for the comparative analysis and synthesis of different applications or similar approaches in the automotive manufacturing industry companies (global and local) and lean product development processes in the field study of the research, under qualitative data. Under the AHP mathematical model created in the research, it was aimed to measure interdisciplinary clusters with a focus on new technology and to identify similarities or differences under alternative applications created by different company structures and to compare them systematically and evaluate them mathematically. In the study, the AHP mathematical model was used to compare lean product development processes and the use of new autonomous vehicle technologies, and the Expert Choice program was preferred in the application of the method.

Autonomous Vehicle Design in Lean Product Development Processes for Value Stream Map

The global automotive industry is giving a difficult and common test in order to create advanced life models in the near future plans or scenarios that include current autonomous vehicle technologies. Therefore, the main purpose of the research is to comparatively evaluate the impact of autonomous vehicle technologies, which are newly included in the automotive manufacturing industry under sustainable competition, on lean product development processes, value acquisition and preservation, in different organizational structures in the approach. Although mergers or brand acquisitions in the global automotive industry create joint R & D (Research Development) or joint new P & D (Product Development) process structures for the development of autonomous vehicle technologies, heavy competition continues in the market. These new processes create different needs for the merger and partnership of the renewed traffic infrastructures under national and international regulations, and for the implementation of the new autonomous life model. Firm and brand marriages, mergers or acquisitions in today’s automotive industry have ensured the high diffusion of lean product development processes under the stream of value creation or preservation carried out specific to the company under competition. Brand mergers in automotive industry companies struggling to survive under high competition create new work disciplines, professions, and engineering flow steps in lean product development processes. However, lean product development processes driven by technological innovation under simplification have resulted in the integration of parts and systems within the autonomous vehicle design structure, as well as creating new interdisciplinary value streams or different stakeholders. Therefore, the research revealed the significant effects of lean product development processes on the value stream in the automotive industry, on the mixed and lean product development process structure formed by new or existing vehicle systems (conventional vehicle) under the penetration of each existing and new discipline. This research compares the efficient operation steps of the process stakeholders in the autonomous vehicle design parts or systems containing innovation and new technology together with the value stream in the lean product development process, and the new process stakeholder’s business-oriented global and local automotive industry companies. New autonomous vehicle technologies, together with their unique software, hardware and development analysis, have been involved in the lean product development process with their interdisciplinary studies or expertise. Therefore, the study firstly focused on the technologies in environmental use together with the new basic features of autonomous vehicles, and then examined in depth the new or existing disciplines and interdisciplinary basic structure that these innovations affect under the value stream in the lean product development process. In addition, micro-level results and recommendations were shared, shedding light on how autonomous vehicle levels will create changes in the new product development process.

企业—用户互动、敏捷开发与数字产品创新绩效

数字技术的可重新编程性、开放性等特征增强了市场需求的不确定性,企业通过与用户互动进行敏捷开发以提升数字产品创新绩效,成为获取竞争优势的关键。基于精益创业理论和利益相关者理论,深入分析企业—用户互动、敏捷开发与数字产品创新绩效间的作用机理。结果表明:企业—用户互动通过敏捷开发积极影响数字产品创新绩效,且组织创新氛围将增强三者间的作用关系。研究有助于丰富对于数字情境下企业—用户互动创新的理解,推动敏捷开发研究的发展,为解释数字产品创新绩效差异化提供有价值的研究思路,也为数字产品创新绩效的提升提供重要的管理启示。

Approaching lean product development using system dynamics:investigating front-load effects

Competing with successful products has become perplexing with several uncertainties and transmutes from time to time as customers＇ expectations are dynamic.That is why manufacturing firms exhaustively strive to look for a better competitive frontier using wellestablished and innovative product development（PD）processes.In this paper,we would like to answer three research questions：（i）What would be the effects of frontloading in PD？（ii）Can we improve our PD process endlessly？（iii）When is the critical time that the firm should take remedial action for improvements？As a contribution to the vast numbers of improvement methods in new product development（NPD）,this paper investigates the effects of front-loading using set-based concurrent engineering（SBCE）on cost and lead time.Models are developed and treated using a system dynamics（SD）approach.We assign a hypothetical upfront investment for SBCE and compare its effects on total cost and lead time of the development process.From the research,it is found that the total cost of PD is reduced almost by half-although the front loading is higher in order to encompass multiple design alternatives.The total product lead time is reduced by almost 20%.The model reveals the critical time for improvement of the PD process.We use SD tool（e.g.,STELLA）for simulation and visualization of the complex PD model,using SBCE as one of several strategies to frontload activities in the NPD process.

一款大功率发电用气体机开发研究

大功率发电用气体机有着较大的市场需求,开发满足客户需求的气体机有着重要的意义。本文通过分析产品的开发要求,确定了稀薄燃烧、米勒循环和高能点火的技术路线,同时对产品进行整机系统设计、系统控制设计以及系统改进设计,并通过试验测试获得发动机的关键参数。试验结果表明,本次开发的大功率稀薄燃烧气体机具有良好的性能,满足设计要求,相关方案可以为类似产品的开发工作提供参考。

面向精益生产的集成化车间生产管理系统开发

针对某制造型企业的生产管理需求,提出了基于精益生产的集成化车间生产管理。调研了企业信息化中存在的问题,借助准时制及精益生产主要技术手段重构企业生产管理业务流程,建立了集成化的系统模型,实现车间生产管理信息集成。完成了生产管理系统架构设计、功能结构设计和数据库设计,基于J2EE平台完成了系统的开发。通过系统实施有效地实现了生产过程的信息集成和资源优化配置,提升了企业快速响应能力。

先进生产方式下的产品开发

文章根据现代生产组织方式及现代产品开发的特点和要求,通过对三种生产方式下产品开发模式的特征分析,探讨了各种不同产品开发方式的异同点,指出了基于精益思想的产品开发适合单一项目管理,基于模块化技术的敏捷产品开发有利于多项目管理,而大规模定制下的协同产品开发是跨公司的多项目管理。为现代企业根据自身现有生产条件和产品特点选择适当的产品开发模式提供一些参考。

基于精益-敏捷创新模式的新产品开发研究

本文首先在借鉴与归纳前人研究成果的基础上,结合先进企业精益-敏捷创新的案例,总结出精益-敏捷创新的概念和五大原则。精益-敏捷创新是一种以用户为中心,提倡进行"验证性学习",然后通过不断试验和学习,以最小的成本和有效的方式验证产品的快而好的创新模式,在精益-敏捷创新过程中要遵循用户场景价值原则、用户参与原则、资源导向原则、最简模型及快速迭代原则。本文最后形成了基于精益-敏捷创新模式的新产品开发过程,该过程包括计划、分析、开发及检验、实施四个阶段。

汽车行业ERP开发和应用模式

根据总结多年在汽车行业ERP及相关IT项目的开发和应用中的实际经验 。

浅谈我国CIMS发展概况

概述了计算机集成制造(CIM)的概念、计算机集成制造系统(CIMS)的构成以及实施 CIMS 的必要性,介绍了我国 CIMS 的发展现状,分析了新一代 CIMS 概念的产生背景及其特点。

地下矿山生产短间隔控制管理研究与系统开发

随着我国智能矿山建设的持续推进与深入应用,生产过程管控的数字化与信息化已成为矿山智能生产的重要内容,其关键在于大幅提高对于生产信息在内容上的精确把握程度与时效上的精准控制水平。为了解决地下矿山传统生产调度组织方式在生产调度的透明性与可控性等方面存在的不足,引入了短间隔控制(Short Interval Control,SIC)这一高频率控制和响应的管理方法。在分析地下矿山生产SIC管理核心需求的基础上,以形成面向SIC的高频调度管控业务模式为目标,构建了包括作业计划制定、短间隔调度排产、短间隔检查反馈和短间隔分析改进在内的地下矿山SIC业务模型。以此为基础,提出了基础通信网络、管理端、移动终端、查询端和工业大数据平台端相结合的SIC跨平台运行体系,设计了面向SIC的生产管理系统功能体系,并完成了系统开发与实现。将该系统应用于国内某大型地下矿山调度管理工作后,全面提升了采矿生产的技术经济效果,表明SIC理念的引入有助于全面改善地下矿山传统调度方式,通过信息化手段完成SIC管理过程可实现生产进度高频监控和闭环反馈,有效提高地下矿山调度管理效率和生产透明度,全面推进智能矿山中生产作业管理的精细化。

数字化油气田精益生产研究

为了应对油气田面临的能源保障任务重、新动用资源品位低、老油气田稳产难、安全环保责任大的严峻形势和解决当前生产过程中存在的问题,有必要借鉴日本丰田汽车公司等制造业精益生产的先进经验,结合油气田开发业务的内容和特点,深入开展油气田精益生产研究。通过分析当前油气田生产过程中存在的问题,明确了精益生产的内涵和总体思路,确定了实现精益生产的对策,为推动数字化油气田开发方案编制、产能建设、生产运营全业务链、全生命周期的精益生产,促进上游业务高质量稳健发展奠定了基础。

基于精益思想的产品开发研究

本文首先介绍了精益思想的基本要素,例如准时化生产、“看板”、团队工作和拉动式生产等。并提出了精益思想在产品开发中的应用,同时利用这些理念来解决产品开发存在的问题,最后作者给出以精益思想为基础的产品开发案例。

面向环境的精益供应链管理

当前,资源紧张和环境恶化已成为全球性的两大难题。在有效控制生产成本的同时,将资源浪费和环境污染降至最低,已成为企业可持续发展的必然选择。文章简介了绿色制造和精益生产的基本内涵,分析了面向环境的精益供应链的构建原则,提出了一种面向环境的精益供应链结构模型,并分析了其运作机制。

油气田地面生产系统提质增效助力上游业务高质量发展

针对油气田地面系统规模庞大、结构复杂的特点,中国石油所属油气田公司开展了系统优化简化、标准化设计、完整性管理、优化运行、技术攻关等提质增效工作,取得了显著成效,降低了投资与生产成本。加强地面生产系统管理,促进系统提质增效,是实现油田效益开发、建设绿色矿山、引领创新发展的必然手段,为此,应着力做好对标分析、地面工艺简化、整体系统优化、生产运行优化、完整性管理、精益生产、产品增值、绿色矿山建设、技术攻关等方面工作,实现老油田有效稳产和天然气快速上产,助力上游业务高质量发展。

面向绿色制造的精益供应链设计

面对全球资源紧张、环境日益恶化和经济一体化趋势,企业要保持可持续发展,必须在有效控制生产成本的同时,将其环境污染和资源浪费降至最低。首先简要地介绍了绿色制造和精益生产这两种先进制造模式,然后将其在供应链中集成起来,构建了一种绿色精益供应链的框架结构模型,最后分析了绿色精益供应链的一般构建原则。

基于精益思想的新产品开发流程再造研究

随着我国建设创新型国家步伐不断加快,集成电路研发国产化需求迫切的环境下,文章进行了基于精益管理思想的新产品开发流程方法的探索性研究。通过对国内集成电路新产品开发现状的分析,文章将精益管理思想引入新产品开发流程中,结合国内集成电路新产品开发过程中的实际问题,阐述了通过运用精益思想的五大基本原则,有效实现新产品开发流程再造的方法,以达到企业持续改善,不断增值的目的。

精益管理理念在轨道交通车辆产品研发中的应用

通过列举一些可以在轨道交通车辆产品设计过程中运用的精益理念和方法,结合目前国内外对于精益管理思想的具体研究与应用情况,提出将精益管理的理念应用到轨道交通车辆产品的研发设计中来。阐述了如何在轨道交通车辆产品研发过程中应用精益管理理念,并提出了进行产品精益设计的一些建议:确保满足用户的需求,充分用精益西格玛设计方法,产品的成本核算贯穿全过程等。