Tools for lean product and process design Competitive and sustainable manufacturing relies on quick adaptation to market needs while considering the entire product life cycle. EU-funded scientists developed tools to add value while minimising waste. Digital Economy © Thinkstock Lean manufacturing refers to a business model and associated methods to eliminate non-value–added activities that waste resources for more efficient production and better product quality. The EU-funded project 'Lean product and process development' (LEAN PPD) pushed the frontiers of lean manufacturing with methodologies, information technology tools and training games. Project scientists developed the LEAN PPD paradigm, including the LeanPPD model, associated tools and guidelines. The LEAN PPD paradigm is one of lean thinking throughout a product's life cycle to enable higher-quality, and more sustainable and affordable products that meet the needs of customisation. A user-driven approach was ensured by consideration of five business cases from end-users in different industrial sectors of the consortium with a focus on automotive, aerospace and home appliance manufacturers. A self-assessment tool, the Lean T2 Transformation Toolkit, helps companies identify their current state and define a roadmap toward lean thinking using qualitative and quantitative key performance indicators. A product development modelling and mapping tool — Value Identification and Waste Elimination tool, focuses on value creation and waste minimisation. This is achieved by capturing the time, cost and resources of current and future (mapped) processes to improve them according to lean principles. The lean design guidelines tool, or Set-Based Lean Design Tool, ensures that lean techniques applied during the design phase are compatible with lean manufacturing methods. Finally, a knowledge-based engineering (KBE) tool automatically checks design rules to ensure compatibility with manufacturing processes for faster deviation corrections. The KBE also includes a cost estimation tool to compare the cost of building a part using different methods. Implementation of the LEAN PPD paradigm and tools is expected to have significant impact on EU large industries as well as on small- and medium-sized enterprises. A shift in focus from waste reduction to value creation will enable manufacturers to quickly respond to market trends for an important boost in global competitive position. Keywords Lean manufacturing, information technology tool, key performance indicators, set-based, knowledge-based engineering
