Formation of
GVE Council
-Dismantle parts
-Grouping / Organize into sub-assembly
-Display / Visual Management
Step 1
Product Tear Down
-First Who…..then What
-Concurrent team approach
-Engineering, Production, Quality Control,
Purchasing, Sale, Maintenance,
Product Design
-Component cost analysis
-Sorting using Pareto Chart
-Identify Vital Component for improvement
Step 2
Prioritization
Step 3
-VOP : Verb-Noun function expression
-VOC : Adverb-Adjective function expression
Function Analysis
-Compare with competitors
-Idea generation using
4 guiding questions
Q1: weight reduce
Q2: geometry reduce
Q3: alternative cheaper material
Q4: lesser scrap residual
-Refine idea and select design
-Change and develop design
-Potential risk analysis – FMEA
-Pilot test / Prototyping
-Quality evaluation (internal / external)
-Customer approval
Step 4
Comparative Analysis
Step 6
Validation
Step 5
Creation
OK
NG
Step 7
Completion
-Follow up
-Financial effect
-Reporting
Figure 3: Lean Product Design Roadmap developed by Oh (2011).
parts. These will drive down labour, overhead
and material cost components of TC.
Q-Costs are on line quality control activities
conducted at the production stage where
raw materials or parts are being transformed
mechanically or chemically by series of processes
to become final product. These activities include
reduction of process variations that become the
origin of product deficiencies, inspecting ma ѕɥ