• Lean Product Development

Bring Your Best Ideas to Market

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 presents Lean concepts, tools, and methods essential to the Toyota Product Development System (TPDS). Collectively, these objectives will prepare you to implement Lean development in your organization and bring your best ideas to market as effectively and quickly as possible. Attendees regularly see process improvements ranging from 30–60% reduction in lead time, 10–20% reduction in rework, and better communication between departments.


Key Learning Outcomes

  • 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 Overview

Each day offers a set of learning objectives that enable product development engineers and new product team members to understand and appreciate the Lean product development process and its tools.


Overview of Lean Product Development and Processes

  • 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

People Systems and Lean Tools of Product Development

  • 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
    • Reflection exercise
    • Checklists and matrices
  • Tools for communication and alignment
    • Hoshin management overview
    • A3 reports overview  – 4 types
    • Nemawashi
    • Obeya

Lean Value Stream Mapping for Lean Product Development

  • Introduction
  • Differences between manufacturing and product development value streams
  • VSM icons for product development
  • Current state map building blocks
  • Build a current state map
  • Current state map exercises
  • Identifying waste in the current state map
  • Build future state map
  • Implementation

A3 Thinking for Lean Product Development: Case Studies and Applications of Lean PD Principles

  • 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

Leading the Change to Lean Product Development

  • 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

Program Faculty

John Drogosz

John Drogosz

Lean Specialist and Lecturer,
University of Michigan College of Engineering

Vice President for Lean Services,
Optiprise, Inc.

John Drogosz, Ph.D. is a Senior Lean Consultant at Optiprise, Inc. with close to 20 years of experience. He conducts Lean Enterprise Rapid Improvement workshops at Northrop Grumman Ship Systems and Value Stream Mapping and Rapid Improvement workshops with Johnson Controls in Asia. Dr. Drogosz, a Six Sigma Black Belt, teaches Lean accounting, Lean engineering and Lean manufacturing at the University of Michigan.

More About Dr. Drogosz

Materials and Resources

Lean PD - Textbook

Resource Text

Provided in Course

In addition to course slides and case studies, The Toyota Product Development System: Integrating People, Process, and Technology is provided as part of the course. This textbook 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.