Leveraging a Process-Oriented Perspective on Frugal Innovation Through the Linkage of Lean Product Development (LPD) Practices and Waste

Frugal innovation aims to attain significantly cheaper solutions on the market. The literature points out a lack of studies addressing frugal innovation from a process-oriented (ex-ante) perspective, as well as how to structure and leverage the frugal product development process. This paper explores how lean principles and fundamentals, and more particularly lean product development (LPD) can help fill this gap. The incidence of different types of waste has been observed throughout the new product development (NPD) process, and their mitigation could certainly leverage frugal innovation from the process perspective. However, to operationalize waste mitigation, an evaluation of how different types of waste are related to the various existing LPD practices is necessary. We accordingly build a relationship matrix between LPD practices and waste mitigation throughout the NPD process, based on a literature review encompassing 310 studies. By correlating LPD practices and waste, this paper proposes and discusses a conceptual model that brings insights to understanding how LPD can drive frugal innovations from an ex-ante perspective. The contributions of this paper are the categorization and classification of waste within NPD; the assessment and classification of the lean practices most studied in the literature; the association of the categories of waste with the corresponding lean practices; and the discussion of the possible contribution of LPD literature to leverage frugal innovation from a process-oriented perspective.

Physics-based trade-off curves to develop a control access product in set-based concurrent engineering environment

Purpose This paper aims to present a process to generate physics-based trade-off curves (ToCs) to facilitate lean product development processes by enabling two key activities of set-based concurrent engineering (SBCE) process model that are comparing alternative design solutions and narrowing down the design set. The developed process of generating physics-based ToCs has been demonstrated via an industrial case study which is a research project. Design/methodology/approach The adapted research approach for this paper consists of three phases: a review of the related literature, developing the process of generating physics-based ToCs in the concept of lean product development, implementing the developed process in an industrial case study for validation through the SBCE process model. Findings Findings of this application showed that physics-based ToC is an effective tool to enable SBCE activities, as well as to save time and provide the required knowledge environment for the designers to support their decision-making. Practical implications Authors expect that this paper will guide companies, which are implementing SBCE processes throughout their lean product development journey. Physics-based ToCs will facilitate accurate decision-making in comparing and narrowing down the design-set through the provision of the right knowledge environment. Originality/value SBCE is a useful approach to develop a new product. It is essential to provide the right knowledge environment in a quick and visual manner which has been addressed by demonstrating physics knowledge in ToCs. Therefore, a systematic process has been developed and presented in this paper. The research found that physics-based ToCs could help to identify different physics characteristics of the product in the form of design parameters and visualise in a single graph for all stakeholders to understand without a need for an extensive engineering background and for designers to make a decision faster.

Lean Maturity Assessment in ETO Scenario

The obligatory path towards a lean manufacturing organization requires assessment and monitoring. However, a lean assessment framework is not yet available for the engineer to order (ETO) scenario. This work explored ten lean ETO maturity principles—identified from the literature—that take insight from three formally defined sets (Toyota Way, lean construction, and lean product development principles). A practical assessment model was proposed based on the evaluation of ten lean ETO objective criteria (four with mathematical formulation) and was validated on a real industrial case. A problem-solving tool, including a new lean tool, called the Problem Focus Matrix (PFM), was also presented; this tool was aimed toward development of an integrated framework that would include the organization mission, management, and continuous improvement.