Conference
Presentations
CASE
STUDY
Systems Approach to Lean Design
Daniel F. Cheeseman
Senior Engineering Director
Raytheon
The current complexity of today’s systems require
significant system engineering discipline to assure not only a performance based design
but a truly affordable one that achieves the essence of a Six Sigma Design. Using the
current systems model deployed on the US Army Excalibur Precision Attack System, a review
will be made of the current model's tools and strategies being deployed by Raytheon
Missile Systems to assure that customer satisfaction is achieved in cost, schedule and
performance. A cradle to grave approach.
Daniel Cheeseman is a Senior
Engineering Director/Fellow/Scientist with 28 years of aerospace engineering experience in
the civilian and military sector. His assignments have included the following: Senior
Engineering Fellow, Senior Research Scientist, Systems Technical Director, Program
Management, Product Assurance Directorate, and Command of USAF Wing Level Assets. He has
extensive experience in team building, technical management and development skills, staff
development /coaching and enhancing financial performance with continuous engineering
process improvement with a Six Sigma robust and affordable design focus. His program focus
during the past five years has been Large Scale Architectures and " System within
Systems " design.
CASE
STUDY
Effectively Applying Lean Design in the Shipbuilding Industry
 Lee A. Duneclift
Senior Project Engineer
NASSCO
This presentation will review program lessons learned from
company-wide deployment to achieving bottom line results, including addressing issues at
all levels of the organization and setting expectations. Mr. Duneclift will highlight both
benefits and potential pitfalls including the all important implementation phase. The key
takeaways will be experience-based recommendations for anyone who is anticipating
deploying Lean Design.
Lee A. Duneclift– is a
Senior Project Engineer at National Steel & Shipbuilding Co. (NASSCO, a General
Dynamics company). He is directly responsible for managing R&D initiatives, process
improvements and build strategy development. He has 23 years experience in the marine
engineering, offshore and petrochemical fields. Before joining NASSCO he held positions at
several major international Engineering & Construction companies.
During the past 16 years at NASSCO in San Diego he has played a
leadership role in all ongoing commercial and government programs, including the National
Shipbuilding Research Program and Navy sponsored R&D projects. He is published in the
Journal of Ship Production for his work on Concurrent Engineering, Machinery Space design
and unitization manufacturing techniques.
CASE
STUDY
Applying Lean Design Principles to Re-Engineer and Existing Product in a Small Company
Context
 Stephen J. Sorocky
CEO and Director
Dynacon, Inc.
While lean design provides its largest benefits when
applied from the start in new product development—the so-called clean sheet
design— this talk will address the application of lean design to an existing clinical
laboratory automation product in the field that requires improvements to cost,
serviceability and reliability. Lessons learned and results will be presented as well as
the considerations resulting from implementing lean design within the constrained
resources of a small company and short schedule.
CASE
STUDY
Clean Sheet—The Lean By Design Development of the Precedent Golf Car
 Dave Hardy
Executive Program
Director
Club Car, Inc.
In January 2004, Club Car Inc., a division of Ingersoll Rand
introduced the Precedent golf car to rave reviews from the market place. The radically
redesigned product focused on features and benefits that golfers and golf course owners
love.
Mr. Hardy will walk you through the "clean sheet"
approach that Club Car took to both its product design and manufacturing processes. By
implementing "Lean By Design" principles throughout the process, Club Car was
able to: reduce parts (operations and fasteners) by 40%, create a new manufacturing
environment focused on quality and a lean supply chain and gain substantial efficiencies
in transportation, order entry and other operational areas.
Dave Hardy graduated from New
Jersey Institute of Technology in Newark, NJ with a BS in mechanical engineering in 1970.
He did graduate level work at the University of South Carolina in Columbia, SC also
concentrating on mechanical engineering. He entered the golf car industry in January, 1976
with the E-Z-Go division of Textron in Augusta, GA as a Design Engineer. He began his
employment with Club Car Inc. in 1978 also as a Design Engineer and is still employed
there today. He has held the title of Design Engineer, Manager of Testing and Development,
Manager of Product Safety, Marketing Manager, Director of Product Development, Director of
Product Safety and Executive Program Director. As Executive Program Director, Mr. Hardy
was given responsibility for the development of the Precedent golf car. Mr. Hardy is
the past President of the National Golf Car Manufacturers Association. During his tenure
with the Manufacturers Association, he was instrumental in the development of safety
standards for golf cars and personal transport vehicles as well as guidelines for their
use.
CASE
STUDY
Incorporating Lean Design into Traditional
Product Development
 Paul Layton
Product Development
Manager
DICKEY-john
This case presentation will review the development
process for DICKEY-john’s new Hand Held Grain Moisture Tester, the M3G. Mr. Layton
will discuss DICKEY-john’s incorporation of Lean Design Methodology to its
traditional concurrent engineering approach to product development and the resultant
impact on design time, company-wide communication and cost. Lessons learned and remaining
obstacles will be examined.
Paul Layton earned a B.S.E.E. Louisiana
State University in 1986. With ESCO Corporation, he was assigned to the design team
responsible for the RADAR Set Test Station, which is used for rapid test and repair of the
F/A-18 weapons RADAR. He later assumed multiple design, test, and manufacturing roles with
Long Elevator and Machine, a passenger elevator company. Paul is currently a Product
Development Manager with DICKEY-john Corporation. His 18-year involvement in design and
manufacturing includes a variety of positions, most with significant leadership
responsibility. It was in his current role that he was exposed to the Munro Lean Design
philosophy and has championed its use in product development at DICKEY-john.
CASE
STUDY
The Boeing 7E7—Developing the New Interior for the New World
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Peter S.
Guard
7E7 Interior Architecture Leader
The Boeing Company |
Nancy E.
McCutchin
7E7 Interior Architecture Leader
The Boeing Company |
The 7E7 Interior development project is utilizing breakthrough
teaming and engagement methods to influence the way we design and build airplanes.
One of the core methods we are using to drive our culture
change is "Lean Design". By having a lean and efficient design,
we enable lean manufacturing and can drastically reduce part count and
flow of the 7E7 assembly process. We will share our
design& manufacturing process by following "A Day In the Life of an
Interior Part" as it moves through the value stream.
Pete Guard is facilitating the
7E7 interior development and integration. He holds BS in Polymer Chemistry from Syracuse
University and has held leadership positions at Boeing, GE and Brunswick focused on
transportation development in aerospace, automotive and marine market segments.
Nancy McCutchin is facilitating the
7E7 development and integration. She attended Pacific Lutheran University and has a
BA in Music Education. As a Manufacturing Supervisor for Boeing, she managed the
installation of interiors for the 777. Previous assignments include Business
Management and Continuous Quality Improvement activities.
CASE
STUDY
Controlling New Product Costs Through Trend Analysis
 Terry Ayer
Value Engineering
Program Manager
Teradyne
In today's competitive market it is necessary to
confirm product costs as early as possible in order to maintain profit margins. New
product funding is normally based on early estimates of cost. Changes during development
often impact the final cost. How can these changes be monitored to insure the cost targets
have not been exceeded?
Mr. Ayer will examine the use of trend analysis as a technique to
more accurately estimate the cost of a new product. Analysis data is used to develop a
target bill of material. DFMA software is used to evaluate early concepts for comparison
to the target.
Terry Ayer has been in his current
position for four years and heads a department exploring how to influence design in the
development stages. Their current objective is to accurately estimate the cost of new
products and control that cost through development. Prior to his work at Teradyne, Terry
spent years at Xerox Corp and fourteen years with Digital Equipment Corp introducing new
products into manufacturing. He has an extensive background in electro-mechanical and
electronic component fabrication as well as broad experience in the processes required to
assemble components into a final product.
CASE
STUDY
Getting From Where We Are
To Where We Want To Be
 Jay Mortensen
Director of Target Costing
and Cost Engineering
Maytag
How do we go from where we are to where we
want to be in the Target Costing process? This presentation focuses on the tactics and
techniques for applying Target Costing tools into an existing robust product development
process. It assumes most organizations are already using some aspects of target costing
but not the complete process. Topics covered include reducing product development time,
early identification of the cost of design, joint development of products with the supply
base, tracking the impact of design changes, and elimination of "gaps" before
production begins. Lessons learned about resource requirements, team building, and gaining
inter-departmental support are integrated into the presentation.
Jay Mortensen is the Director of
Target Costing and Cost Engineering at Maytag. He is a C.P.A. and holds a B.S. in
Accounting from the University of California. He has over twenty years experience in
manufacturing and related responsibilities at Deloitte Touche Tohmatsu, Toyota, Mercury
Marine, and Maytag. His current focus is the implementation of the Target Costing process
at Maytag.
CASE STUDY
What You REALLY Need to Know About Target Costing: 5
"gotta knows" for Yielding Appropriate Cost Product Designs
 Greg Olson
Principal Manufacturing Program Specialist
Rockwell Collins
This is not another Target Costing seminar.
Rather, it is a collection of "gotta knows" gleaned from several pleasant
successes (and a few miserable failures) in the product development trenches. The
presenter will begin with a (very) brief overview of Target Costing fundamentals followed
by brief "mini presentations" of his 5 Target Costing "gotta knows."
If you mess up on any one of these five simple points, your project will suffer.
If you successfully apply these five simple points, your project will benefit.
No prior knowledge of Target Costing (or related disciplines) is assumed.
Greg Olson is
currently a Principal Manufacturing Specialist
in charge of CAIV (Cost As Independent Variable) for a large
military communications development program at Rockwell Collins in
Cedar Rapids, Iowa. He has held various positions at Rockwell
Collins for the past 18 years
(RF/microwave design
for GPS receivers, project engineering, DTC (Design to Cost) /
Target Costing) and has been actively involved in both the "nuts and
bolts" and management of Design to Cost, Target Costing, and CAIV
since 1995. From 1998 – 2003, he served as a participant in the
CAM-I CMS Target Costing
Interest Group.
Greg is a BSEE, 1983
graduate of University of Texas at Arlington.
FEATURED
PRESENTATION
Hitting the Target, The CAM-I Target Costing
Implementation Guide
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Tami L. Capperauld
Leader of the Market- Driven Target Costing Implementation Group
Boeing Commercial Airplanes |
Dr. Shahid
L. Ansari
Professor of Accounting Information
Systems
California State University Northridge |
The Consortium for Advanced Manufacturing –
International (CAM-I), Target Costing Best Practice Interest Group developed an actionable
Target Costing Implementation guidebook that will enable companies to understand the how,
when and why of implementing this important strategic management process. This
presentation will cover the key learning points from the guidebook outline.
- Build a Support Base
- Establish Charter for Target Costing
- Develop Implementation Plan
- Build Teams for Target Costing
- Provide Training
- Acquire Tools
- Develop Action Plan to Achieve Goals
- Institutionalize the Target Costing Process
Tami Capperauld, Senior Finance
Business Analyst and Leader of the Boeing Market Driven Target Costing (MDTC)
Implementation & Support Group, has been a member of Boeing Commercial Airplanes (BCA)
for 14 years focusing on development and implementation of advanced cost management
methods and processes. As a pioneer in Target Costing for BCA, she has both led and
participated in implementing MDTC on several major airplane programs.
Tami is currently the Lead and Subject Matter Expert for MDTC
Implementation in Boeing Commercial Airplanes and a Steering Committee Member for the
Boeing Company Affordability Process Action Team. She is responsible for conducting
Program Leadership Team overviews, Program Process Maturity Assessments, preparing
implementation plans and tailoring the implementation strategy and approach. She is a
highly rated MDTC Workshop Instructor for The Boeing Company.
Dr. Shahid L. Ansari has many years of experience in
teaching, scholarly research, and consulting. He received his Ph.D.
in Accounting and Organizational Behavior from Columbia University
and has taught in graduate and undergraduate programs at UCLA, NYU,
and the Naval Postgraduate School. He has also been a Visiting
Faculty at INSEAD, Fontainebleau, France, Macquarie University,
Australia and Pretoria University, South Africa, Marshall School at
USC, and the Shell Learning Center in Houston and Holland and Rice
University. Dr. Ansari has won several awards and honors for
distinguished teaching during his career.
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