Development Benchmark
Report
May 2007
Lean Product Development
Page 2
Executive Summary
Lean concepts have helped manufacturers streamline processes and reduce Exmark Manufacturing Co. Inc.,
a division of The Toro
cycle times in complex manufacturing and supply chain environments. These
Company
concepts are now being applied to product development, resulting in
increased productivity and greater ability to develop profitable products. We have fostered a Lean
culture through “top down”
Best in Class Performance and “bottom up” corporate
lean objectives. We have
The top 20% of companies benchmarked – the Best in Class – enjoy a
robust new product
significant performance gap over their competitors in meeting targets for development (NPD) processes
product launch dates, product development costs, product cost, product that are documented and
revenue, and quality. They are hitting these targets that drive profitability on continuously evolve as we
over 80% of their products while average companies hit these targets less learn, enabling us to reduce
than 60% of the time. As a result, Best in Class performers enjoy 53% more non-value-added steps or
productive product development time per person than their average processes.
competitors, and bring products to market 25% faster on average.
Competitive Maturity Assessment Dave Converse, Director of
Engineering
Survey results show that Best in Class firms share an increased focus on
Lean Product Development. Specifically, Best in Class companies are 1.4
times more likely to have pursued Lean Product Development for more
than one year than average companies. These companies leverage current
best practices and PLM technologies and extend them with Lean capabilities
to improve product profitability.
Required Actions
In addition to the specific recommendations in Chapter 3 of this report, to
achieve Best in Class performance, manufacturers must:
• Streamline processes, including improving process flow and aligning
information with processes.
• Reduce wasted effort, including elimination of non-value added steps
and automating redundant tasks.
• Reduce variability, by standardizing work processes and deliverables
and reducing risk through the use of design sets.
• Validate designs early, co-develop and validate products to confirm
manufacturability and prevent design rework.
• Develop a Lean culture by enabling change at all levels and measuring
product development with metrics.
Table of Contents
Executive Summary....................................................................................................... 2
Best in Class Performance ......................................................................... 2
Competitive Maturity Assessment........................................................... 2
Required Actions ......................................................................................... 2
Chapter One: Benchmarking the Best in Class...................................................... 4
Lean Product Development: Aberdeen Analysis .................................. 4
Maturity Class Framework ........................................................................ 4
Key Measure of Lean: Percent of Value-Added Effort......................... 5
Best in Class PACE Model ......................................................................... 6
Key Measure of Product Development: Time to Market................... 7
Chapter Two: Benchmarking Requirements for Success .................................... 8
Competitive Assessment............................................................................ 8
Organizational Capabilities and Technology Enablers .......................10
Chapter Three: Required Actions .........................................................................13
Laggard Steps to Success..........................................................................13
Industry Average Steps to Success.........................................................13
Best in Class Steps to Success ................................................................14
Appendix A: Research Methodology.....................................................................16
Appendix B: Related Aberdeen Research............................................................19
Figures
Figure 1: Top Performers Hit Targets, Earn “Best in Class” Status ................. 5
Figure 2: Time Spent on Productive Development Activities ............................ 5
Figure 3: Lean Product Development for More than 1 Year ............................. 8
Tables
Table 1: Best in Class PACE Framework ................................................................ 6
Table 2: Product Development Leadtime – BIC Advantages ............................. 7
Table 3: Competitive Framework ............................................................................. 9
Table 4: PACE Framework .......................................................................................17
Table 5: Competitive Framework ...........................................................................17
Table 6: Relationship between PACE and Competitive Framework.............18
Chapter One:
Benchmarking the Best in Class
Lean Product Development: Aberdeen Analysis Fast Facts
Manufacturers have to bring products to market rapidly and efficiently to √ Best in Class
manufacturers hit product
realize the profit potential of their innovations. This complex process
launch dates 72% more
involves multiple departments and disciplines working together to develop a frequently than average
product that is right for the market – both technically and commercially. companies
Lean concepts, already used to streamline manufacturing operations and
the supply chain, are now being applied to product development in the √ Best in Class
manufacturers hit product
hopes of increasing product profitability.
development cost
targets57% more
Maturity Class Framework frequently than average
companies
Aberdeen used five performance criteria to measure companies’ product
development performance and to distinguish the Best in Class from Industry
Average and Laggards. These five metrics including meeting targets for:
• Product launch dates Boeing
• Product development costs “On the defense side of the business,
• Product costs we have put an umbrella on
• Product revenue improvement processes under Lean.
• Quality There has been a lot of effort on
streamlining processes and reducing
These are the metrics that drive product profitability. The top 20% of NVA (non value added) steps, along
companies benchmarked – the Best in Class – enjoy a significant with a big emphasis on education.”
performance gap over their competitors, hitting these targets on over
80% of their products as compared to average companies who hit most of
these targets less than 60% of the time (Figure 1). Clearly, there is a large Carolyn Castillo, Integrated
difference between the performance of the top twenty percent as compared Defense Systems
to average companies, giving the Best in Class companies a clear competitive
advantage over their competition. The metrics serve as a good measure of
the success of bringing profitable products to market, and are used in this
benchmark to measure the effectiveness of Lean initiatives in product
development.
100% 91%
86% 87%
90% 83% 83%
80% 72%
70%
59%
60% 56% 53%
50%
50%
37%
40% 32%
28%
30% 20% 18%
20%
10%
0%
Launch Date Revenue Product Cost Development Quality
Targets Targets Cost Targets Targets
Key Measure of Lean: Percent of Value-Added Effort Top Priority “Waste” Identified by Best in
Another metric important to measuring Lean initiatives is the percentage of Class
effort spent on “value-added” activities. For example, time spent on projects √ Poor or missing requirements, or
with poor or missing requirements was identified by 47% of Best in Class requirements not aligned with
companies as one of the highest priority “waste” in product development. customer value
Another 44% identified waiting for information from others as non value - √ Waiting for information from
added. By proactively minimizing these “wastes”, Best in Class companies others
increase their product development productivity. In fact, Best in Class
√ Redeveloping redundant designs
performers have 53% more productive time per employee than
average companies. (versus reusing existing designs)
80% 69%
70%
60%
50%
45%
40%
26%
30%
20%
10%
0%
Best in Class Average Laggard
,
r
Chapter Two:
Benchmarking Requirements for Success
Lean Product Development is not a technology. It is a product development
philosophy that encompasses a number of core disciplines. Before Fast Facts
investigating the components of Lean, it is important to establish whether √ Best in Class companies are more
Best in Class companies owe their superior performance – at least in part – than two times as likely to have
to the use of Lean concepts. To this end, over 25%of Best in Class pursued Lean Product Development
companies indicated that they have had a Lean Product for more than 1 year.
Development program in place for five or more years compared √ Twenty-five percent (25%) of Best in
to less than 5% of average companies. In fact, Best in Class companies Class have had a Lean Program in place
are more than two times as likely as average companies to have had a Lean for more than 5 years versus 5% of all
Product Development program in place for more than one year (Figure 3). others.
Competitive Assessment
To analyze the Lean approaches that lead to enhanced performance, survey
respondents were classified into one of three categories – laggard, industry
average, or Best in Class — based on their performance. Then,
characteristics in five key aspects of their business: (1) business process; (2)
organization; (3) knowledge management; (4) use of enabling technology;
and (5) performance management were analyzed. The results of this analysis
were compared to average and laggard performers, and the most
differentiated approaches are highlighted below as a means to understand
what leading companies are doing differently from the rest (Table 3). For
more information on Aberdeen’s Competitive Framework, see Table 5 in
Appendix A.
Chapter Three:
Required Actions
Whether a company is trying to move its performance in product
development from “Laggard” to “Industry Average,” or “Industry Average”
to “Best in Class,” the following actions will help spur the necessary
performance improvements using Lean Product Development techniques: Fast Facts
Best in Class manufacturers are
Laggard Steps to Success adopting Lean Product Development
1. Streamline processes. Put in place cross-departmental product strategies faster than their peers.
development processes, and streamline them to reduce wait times and Leading companies have leveraged a
combination of current best practices
other waste.
in new product development, Lean
2. Reduce wasted effort. Identify and reduce all effort that does not principals from manufacturing, and
provide direct value to the customer (or is an unavoidable cost of doing new Lean concepts specific to Lean
business). Prevent time wasted in search by making information readily Product Development
available in a central location and providing advanced search capabilities.
3. Reduce variability. Reduce waste in the form of variability which
provides unpredictability and prevents continuous improvement by
standardizing work processes and deliverables.
4. Validate designs early. Ensure the designs are correct early in the
development process. Co-develop products to find problems earlier
when they can still be corrected or avoided by utilizing concurrent
design.
5. Develop a Lean culture. Teach employees the fundamentals of Lean
and begin to adopt Lean thinking. Incorporate metrics to measure and
improve product development processes.
Reduce wasted effort. Identify and reduce all effort that does not
provide direct value to the customer (or is an unavoidable cost of doing
business). Automate redundant tasks using tools like workflow and
Knowledge Based Engineering (KBE) or automated publishing solutions.
Prevent time wasted in search by making information readily available in
a central location and providing advanced search capabilities. Finally,
focus development efforts on projects with high customer value and
prevent expending resources on “dead” projects using product portfolio
management (PPM).
2. Reduce variability. Reduce waste in the form of variability which
provides unpredictability and prevents continuous improvement.
Standardize work processes and deliverables across the enterprise.
While variability is inherent to innovation, reduce the schedule risk
associated with this variability by introducing the use of design sets.
3. Validate designs early. Ensure the designs are correct early in the
development process. Co-develop products to find problems earlier
when they can still be corrected or avoided by utilizing concurrent
design and tools like digital manufacturing (DM) and manufacturing
process planning. Validate cost and supply chain performance in advance
to ensure profitability using product cost management (PCM).
4. Develop a Lean culture. Teach employees the fundamentals of Lean,
and allow them to help identify and execute Lean improvements in the
product development process. Incorporate metrics to measure and
improve processes.
risk associated with this variability with the use of design sets, if you
have not already adopted this strategy.
4. Validate designs early. Ensure the designs are correct early in the
development process. Enhance co-development by utilizing concurrent
design and tools like digital manufacturing (DM) and manufacturing
process planning. Validate cost and supply chain performance in advance
to ensure profitability using product cost management (PCM).
5. Develop a Lean culture. Continue to educate the company on Lean,
and allow employees to become change agents to help identify and
execute Lean improvements throughout the product development
process. Ensure that metrics are being measured on a timely basis to
measure and improve product development processes, and make mid-
course corrections to projects.
Appendix A:
Research Methodology
In April 2007, Aberdeen Group examined the use of Lean Product
Development in over 400 manufacturing companies.
Responding executives completed an online survey that included questions
designed to determine the following:
• The degree to which Lean concepts are deployed in their product
development process
• Current and planned use of Lean to improve product development
performance
• The benefits, if any, that have been derived from Lean Product
Development initiatives
Aberdeen supplemented this online survey effort with telephone interviews
with select survey respondents, gathering additional information on Lean
Product Development strategies, experiences, and results.
The study aimed to identify emerging best practices in leveraging Lean in
product development and provide a framework by which readers could
assess and improve their own capabilities.
Responding enterprises included the following:
• Job title/function: The research sample included respondents with the
following job titles: senior management (10%); vice president (5%);
director (22%); manager (29%); staff at (24%); and others (15%).
• Industry: The research sample included respondents exclusively from
manufacturing industries. Industrial Equipment was the largest segment
comprising (26%) of the sample. Aerospace and Defense and Medical
Devices each accounted for (19%) of respondents, followed by
Automotive at (18%). Other sectors responding included
Pharmaceutical Manufacturers and Consumer Electronics at (10%),
Computer Equipment and Peripherals, Chemicals, and Consumer
Durable Goods.
• Geography: The majority of respondents (85%) were from North
America. Remaining respondents were from Europe (12%) and the Asia-
Pacific region (2%).
• Company size: About 31% of respondents were from large enterprises
(annual revenues above US$1 billion); 27% were from midsize
enterprises (annual revenues between $50 million and $1 billion); and
41% of respondents were from small businesses (annual revenues of $50
million or less).
Solution providers recognized as sponsors of this report were solicited after
the fact and had no substantive influence on the direction of the research.
Their sponsorship has made it possible for Aberdeen Group to make these
findings available to readers at no charge.
PACE Key
The Aberdeen Competitive Framework defines enterprises as falling into one of the following
three levels of practices and performance:
Best in class (20%) — Product development practices that are the best currently being
employed and significantly superior to the industry norm, and result in the top industry
performance.
Industry norm (50%) — Product development practices that represent the average or norm,
and result in average industry performance.
Laggards (30%) — Product development practices that are significantly behind the average
of the industry, and result in below average performance
In the following categories:
Process — What is the scope of process standardization? What is the efficiency and
effectiveness of this process?
Organization — How is your company currently organized to manage and optimize this
particular process?
Knowledge — What visibility do you have into key data and intelligence required to manage
this process?
Technology — What level of automation have you used to support this process? How is this
automation integrated and aligned?
Performance — What do you measure? How frequently? What’s your actual performance?
Appendix B:
Related Aberdeen Research
Related Aberdeen research that forms a companion or reference to this
report includes:
• The Product Innovation Agenda Benchmark (September 2005)
• New Product Development: Profiting from Innovation (January 2006)
• Profitable Product Development for SME (March 2007)
• Digital Product Development (March 2007)
Information on these and any other Aberdeen publications can be found at
www.Aberdeen.com.
Author: Jim Brown, Vice President, Product Innovation & Engineering Research
jim.brown@aberdeen.com
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