A Lean study to improve the efficiency and flexibility of the product realisation process

Abstract: This thesis investigates the possible positive effects a Lean study of the, planning, production and development of products, may have on a company’s product realisation process. In an environment where a company needs to satisfy a customer demand for both standard and customised products will induce a wide product range. This can induce a lot of wasteful activities and puts pressure on the product realisation process to be efficient and flexible. The purpose of the thesis was to identify gaps which need to be improved in order to increase the efficiency and flexibility of the product realisation process. In order to study this phenomenon a company that practices both production and development of products, as well as offering both standard and customised products was chosen for a case study. The authors utilised value stream mapping, interviews and observations to establish a great understanding of the company’s activities within the product realisation process. From this, the authors identified gaps that needed to be improved in order to fulfil the standards of ISO 9001 and to increase the efficiency and flexibility within the product realisation process. The study resulted in 15 identified gaps concerning the production and product development departments. Several gaps where chosen for an in-depth study based on their feasibility and potential of improvement. The authors developed several in-depth proposals utilising the Lean philosophy as well as production and inventory control tools, and proven product design techniques. If implemented these proposals would increase the efficiency and flexibility within the product realisation process. The authors suggest that companies should conducting a Lean study of the product realisation process with the purpose to increase the efficiency and flexibility. This will enable a company to identify and improve the proper aspects in order to survive or gain market shares in an environment where the customer demand for standard and customised products needs to be satisfied.