Lean Product Development

Key Information

Course Dates

Time Commitment

5 days

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Optimize your innovative potential with Lean Product Development.

Learn essential strategies and key tools that will decrease time-to-market, reduce waste, enhance product quality, and fully integrate new product designs into a Lean production environment. Leave prepared to bring your best ideas to market as effectively and quickly as possible.


  • 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



Mon-Fri 8:00AM – 4:30PM ET


  • Impact and benefits of Lean PD
  • Overview of Lean PD principles
  • Lean Product Development simulation – Round #1 (traditional PD)
    • Problems with traditional product development
    • Illustration of typical wastes
    • Tracking metrics associated with traditional wastes
  • Processes
    • Driving flow in product development: insights from queuing theory
    • Kentou phase
    • Decision flow mapping
    • Learning cycles
  • Set-based concurrent engineering
  • Intro to people systems
    • Balance functional expertise with cross-functional integration
    • Develop towering technical competence in all engineers
    • Chief Engineer system – abridged version; focus on concept paper/VOC
    • Supplier partnerships
  • Tools for organizational learning and continuous improvement
    • Overview of learning tools and techniques
    • Reflection
    • Checklists and matrices
  • Tools for communication and alignment
    • Hoshin management overview
    • A3 reports overview – 4 types
    • Nemawashi
    • Obeya
  • Differences between manufacturing and product development value streams
  • VSM icons for product development
  • Current state map building blocks
  • Build a current state map
  • Identifying waste in the current state map
  • Build future state map
  • Implementation
  • Applying A3 thinking and problem solving to real-life challenges you are facing at work
    • Define the problem – 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 & applications
    • Case studies of applying Lean PD techniques
    • Lean PD implementation approaches & lessons learned
  • Summary of Lean PD principles
  • Cultural characteristics of Lean PD
  • Simulation Round #2 (Lean)
    • Apply Lean principles from class to the simulation
    • Illustrate the impacts on a PD system
  • Implementation approaches to drive Lean principles in your organization
    • How to get started
    • Lessons learned – what works and does not
    • Implementation examples from selected companies
  • Getting started – A3 proposal for your first steps on the Lean PD journey


This course is intended to benefit professionals involved in:

  • Product planning
  • Product design and development
  • Process development
  • Product and process validation
  • Manufacturing or product launch


John Drogosz

John Drogosz, PhD

  • Lean Specialist and Instructor, Nexus, College of Engineering
  • Vice President, Optiprise Inc.

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