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How You Can Incorporate Lean Manufacturing Into Your Business

There has been a lot of talk about lean manufacturing these days. It has gotten a lot of attention, mostly because of the down economy. Everybody is looking for ways to save money and to become more efficient. Unfortunately, for many businesses, trying to get lean so late in the game is not going to save the inevitable.

That is why it is important to get on the lean band wagon early on. It is going to help make the business strong from early on, right from the start and the chance of back sliding is less likely. When you build from a solid foundation, every facet of the company is stronger, from the employees to the procedures. When every process is developed from the ground up, with best practices and a focus on efficiency, then they have a greater chance to fit together with all of the other departments and process in the best way possible.

It does not make sense to do it any other way if you have a choice. Every builder will tell you that building something new is always simpler than remodeling a preexisting building. There will always be a lot more issues and unexpected distractions then when you begin from the ground up. This is true with retrofitting anything, from an existing machine to an existing process. When you are trying to change something to make it work, you are going to always have a more tough time then if you start from the beginning of a process before it begins.

This is another good reason to get it right the very first time. But getting it right will take a little extra work in the beginning. Sometimes unexpected things happen, processes are pushed upon you that you don’t have time to work out and to try different things, and you just have to get something to work at that moment. However, these types of things are infrequent and can be prevented most of the time.

So taking that additional time early on, putting together a plan which can be looked at and dissected, that works with all of the other processes involved and can be fit together like a big puzzle to work perfectly together is always the best way to go. Because in the long run, you want all of the processes to fit together and operate correctly together without hampering or impeding any of the other processes that they come into contact with.

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How to Reduce Commercial Risk and Have Faster Product Development

Part of the responsibility of a product development team is to reduce both the technical and commercial risk for the company that a project will fail after it is commercialized. Usually, a company will complete a significant amount of research to minimize the technical risk by developing a product that meets the customer’s requirements and can be made economically at production scale.

To address the commercial risk that the team will choose the wrong applications to pursue, project teams use an application map that shows the various likely applications for the new product and the team’s approach to moving through the various applications. The path will be determined based on product performance, customer requirement similarities, and potential profitability.

While the plan will change over time, the application map is a great visual tool for helping the team stay focused on success. Without such a map, it is easy for groups to focus only on a large application that could take 5-10 years to come to commercial fruition. In an economic downturn, management may choose to cut the project.

Other groups might focus only on a small initial market to test the commercial waters and then spend too much time trying to make the product successful in that small initial application, rather than moving on to the next application.

Developing the application map requires joint communication and understanding of target market requirements and technical capabilities between the commercial and technical members of a product development team. To make the most effective use of the products as they are developed, it is important to focus research on developing products that meet the requirements of the initial target markets and then sample to those market segments where the newly developed products can be used.

Not only will this provide a greater return faster on the research that has been done, but it will be easier for the sales organization to convince customers to try the product. Data that other customers have been using the product will have greater impact on customers when they know that the application requirements where the product is currently being sold are similar to their own product requirements.

 

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