The Toyota Product Development System

This title is the winner Of The 2007 Shingo Prize For Excellence In Manufacturing Research! The ability to bring new and innovative products to market rapidly is the prime critical competence for any successful consumer-driven company. All industries, especially automotive, are slashing product development lead times in the current hyper-competitive marketplace. This book is the first to thoroughly examine and analyze the truly effective product development methodology that has made Toyota the most forward-thinking company in the automotive industry.In "The Toyota Product Development System: Integrating People, Process, and Technology", James Morgan and Jeffrey Liker compare and contrast the world-class product development process of Toyota with that of a U.S. competitor. They use extensive examples from Toyota and the U.S. competitor to demonstrate value stream mapping as an extraordinarily powerful tool for continuous improvement. Through examples and case studies, this book 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. Readers of this book can focus on optimizing the entire product development value stream rather than focus on a specific tool or technology for local improvements.

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Foreword Acknowledgments Preface Section One: Introduction Chapter 1: The New Product Development Revolution Chapter 2: The Lean Product Development System Model Section Two: Process Subsystem Chapter 3: Establish Customer-Defined Value to Separate Value-Added From Waste Chapter 4: Front-Load the PD Process to Explore Alternatives Thoroughly Chapter 5: Create a Leveled Product Development Process Flow Chapter 6: Utilizing Rigorous Standardization to Reduce Variation and Create Flexibility and Predictable Outcomes Section Three: Subsystem People Chapter 7: Creating a Chief Engineer System to Lead Development From Start to Finish Chapter 8: Balancing Functional Expertise and Cross-Functional Integration through Organization Chapter 9: Develop Towering Technical Competence in All Engineers Chapter 10: Fully Integrate Suppliers into the Product Development System Chapter 11: Building in Learning and Continuous Improvement Chapter 12: Building a Culture to Support Excellence and Relentless Improvement Section Four: Subsystem Tools and Technology Chapter 13: Adapt Technology to Fit Your People and Process Chapter 14: Align Your Organization Through Simple, Visual Communication Chapter 15: Powerful Tools for Standardization and Organizational Learning Section Five: Creating a Coherent Lean PD System Chapter 16: A Coherent System Chapter 17: Eliminating Waste In The Product Development Value Stream Chapter 18: Getting to Culture Change: The Heart of Lean PPD Appendix Applying Value Stream Mapping to a Product Development Process: The PeopleFlo Manufacturing Inc. Case by Dr. John Drogosz Bibliography Index

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