Lean Product Design for 3P Implementation
Practical Methods for Slashing Manufacturing Costs
Presented by Ron Mascitelli, PMP
President, Technology Perspectives

September 13-14, 2010  -  Dallas, TX

This workshop presents a comprehensive set of practical, easily applied techniques for reducing the manufacturing cost of any product.  For the first time, a straightforward, step-by-step methodology will be presented for the implementation of the powerful Toyota “3P” process (Production Preparation Process).  Students will learn how to apply this proven approach to real products though a series of small team exercises – bring your product ideas to the workshop and take away real-time cost savings! Remember, reducing manufacturing cost is the fastest and surest way to achieve a measurable increase in profits.  The practical tools in this workshop can be applied to both new product opportunities and existing successful products, require minimal demands on scarce resources, and can yield immediate bottom-line results.  Slashing costs is a great place to begin your journey toward lean product development excellence.

Upon completing this course, students should be able to:           
1.  Understand the sources of cost for any manufactured product.           
2.  Utilize twenty cost “levers” to perform cost-reduction trade-offs.           
3.  Improve customer communication and value capture.           
4.  Implement a practical version of Toyota’s 3P process.           
5.  Dramatically reduce the manufacturing cost of any product.           
6.  Ensure the smooth and rapid transition from design to production.

Course Outline
A series of practical workshop exercises accompanies the following lecture agenda.  The output of the workshop is a clear understanding of how to implement these tools, and potentially some real-time cost saving opportunities!

Part I.  Introduction to Lean Product Design
·         When is a Product Profitable?
·         Screening for Profitable Products
·         Defining a Target Cost
·         The “Twenty Key Levers” for Product Cost

Part II.  Capturing the Voice of the Customer
·         Testing for Value
·         The “Lean QFD”
·         Prioritizing Customer Requirements

Part III.  Platform-Based Cost Reduction
·         The Product Line as a “System”
·         Microplatform Strategies
·         Modular / Scaleable Design
·         Mass Customization

Part IV.  Production Preparation Process (3P) Overview
·         Overview of Toyota’s 3P Process
·         How 3P can be Scaled to Meet Your Firm’s Needs
·         A Practical 3P Implementation Strategy

Part V.  Step-by-Step 3P Cost-Reduction Workshop
·         Basics of Value Engineering and Analysis
·         Considering Alternative Designs
·         Identifying Points of High Cost and Quality Leverage
·         The “Quick-Look Value Engineering” Methodology
·         The “Pugh Method” for Concept Selection
·         The “How’s it Built” Review
·         The “Seven Alternatives” Process
·         Manufacturability Modeling and Simulation
·         Fundamentals of Process Design and Optimization

Agenda
September 13. 2010
7:30 a.m.
Registration & continental breakfast

8:00 a.m.
Session begins

5:00 p.m.
Adjourn 

September 14, 2010
7:30 a.m.
Continental breakfast

8:00 a.m.
Session begins

4:00 p.m.
Meeting adjourns

About the Instructor
Ronald Mascitelli, PMP, CMC  (Project Management Professional, Certified Management Consultant; MS Solid State   Physics, University of California, Los Angeles) is the Founder and President of Technology Perspectives.  Mr. Mascitelli     is a recognized leader in the development of advanced project management and product development methods, with an emphasis on eliminating non-value-added waste and maximizing product-line profitability.  He currently presents his workshops and seminars internationally to public audiences, and has created company-specific educational programs for a  number of leading firms, including Lockheed-Martin, Boeing, Anderson Windows, Boston Scientific, New Balance Athletic Shoes, Parker-Hannifin, L3 Communications, Harris Corporation, Rockwell Automation / Allen-Bradley, Applied Materials.

Mr. Mascitelli served as both Senior Scientist and Director of Research and Development for Hughes Electronics and the Santa Barbara Research Center.  His industry experience includes management of advanced product developmentprograms for the Department of Defense, DARPA, Lawrence Livermore Laboratory, NASA, the Army Night Vision Laboratory, and the Department of Energy. 

Since founding Technology Perspectives in 1994, Mr. Mascitelli has published over twenty papers and technical articles in major journals, including the International Journal of Technology Management and The Journal of Product Innovation Management, and is a contributing author for IEEE’s Technology Management Handbook.  Mr. Mascitelli is also the author of a critically acclaimed book on lean project management, entitled Building a Project-Driven Enterprise: How to Slash Waste and Boost Profits Through Lean Project Management, and his latest book, entitled The Lean Design Guidebook.

Who Should Attend
Product designers                                                         
Product-line managers                                                   
Task managers                                                 
Six-sigma blackbelts / green belts                                  
Operations managers                                                    
Manufacturing engineers
Team leaders
Functional managers
Improvement champions
Process owners
All others with product development responsibilities

Location / Hotel
Embassy Suites Dallas Love Field
3880 W. Northwest Hwy
Dallas, TX 75220
PH:  214-357-4500

Association for Manufacturing Excellence discounted room rate of $119.00 (plus tax).  The discounted room rate will end on August 22, 2010,  so make your reservation today!

AME Member: $845.00
Non-Member: $1.045.00
Student Member:  $50.00
Non-Student Member:  $75.00

You can become an AME member during the registration process for $150 per year and obtain the discounted AME member rate for this event.  Your membership will also entitle you to a registration discount for all future AME conferences, seminars, workshops, and webinars.  Additionally, you will receive a subscription to the award winning Target magazine and much more.




Payment or purchase order must be received by the AME office five days prior to the event start date. If no payment or PO number is received, you will be asked to pay with a credit card or check at the event before entry.

Cancellation Policy: Enrollment fee less $100.00 non-refundable registration charge will be refunded up to one week before the event. Substitutions may be made any time prior to the start of the workshop.

Notes:  This event may be cancelled by AME for any reason. AME is not responsible for incidental costs incurred by registrants. By registering for this meeting, I hereby acknowledge and agree that AME or its agents may take photographs of me during events and may use those photographs for AME’s purposes, including but not limited to news and promotional purposes, without further compensation to me.

Fees