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Implementing the lean principles and tools in manufacturing has been successful in many companies. This success has led to different implementations, of these principles, in other organizational activities such as design and management. While these implementations can produce some improvements, the segmentation of the product development processes in most company limits the potential for achieving the desired goals and in some cases the success of the implementation process itself. In other words, full success of lean principles implementation cannot be achieved when applied to isolated segments of the product development process. This paper addresses lean design, in the context of a fully integrated product realization process. The paper discusses the integrated nature of any product realization process and its flow from concept to production.

Virtual Simulations tools are extensively utilized by many industries today in product development processes. In auto industry, however, this utilization has not reached its full potential. So far virtual simulations have been playing a supporting role in traditional product development processes founded on physical builds. To reach the full potential of virtual simulation, in reducing the product development time and costs, a paradigm shift in the product development processes and the role of both physical and virtual simulations is need. For an integrated realization process, innovation, analysis, integration, and continuous correlations are necessary design practices for achieving the desired product attributes. This paper, discusses the expansion of the virtual simulation role in an integrated product realization process to reshape the traditional product development process.

Implementing the Voice of the customer is one of the main challenges during the Vehicle Development Process. The variety of desired vehicle attributes requires well-defined processes that include manufacturability along with the voice of the customer in all aspects of the product development process. Customer's defined attributes along with regulations and manufacturability requirements should flow through all process phases starting from the early concept development phase. This paper discusses a lean design approach to assure that the voice of the customer attributes are addressed and balanced through the product development process from concept to production. The lean approach includes architectural, performance, and manufacturability as key development attributes. A case study of Automotive Modular Door System is presented to demonstrate the application of the lean approach in the design and development of complex automotive systems.

Lean applications in product development usually start with manufacturing due to the relative experience of measuring improvements and identifying wastes in physical settings. The full potential of lean implementation in any product development, however, can only be realized when applied throughout the process, starting with early process. Considering that the first and most essential principle in lean implementation is the characterization of value from the customer's perspective, it is imperative that the proper definition of value is realized at the beginning of the process. In addition, streaming and flowing of this customer's specified value should be realized throughout the process from start to finish. This paper discusses the application of lean principles to integrated design and manufacturing phases of the Product Development Process.

Fundamentals of Integrated Vehicle Realization is a unique and solid contribution to the subject of product development, centered on the automotive industry. Automotive manufacturers and suppliers are under pressure to transform themselves and deliver a higher level of product refinement coupled with more functionality. This could lead to the sprouting of organizational structures not in alignment with the required product development phases. Consequently, many product development initiatives may be cancelled or dropped at later stages despite all the efforts and financial investments. Therefore, it is vital that organizational unity be always intact during any transformation. A highly effective organization should always act as one cohesive entity dedicated to serving the customer with creative aptitude, integrative skills, analytical thinking, and synergistic management. Written by Dr.

Vehicle quality and affordability will always be the most distinguishing summative characteristics in a fully saturated and highly competitive market. While vehicle quality differentiates between brands in any market segment, affordability remains the key decisive factor for many buyers in each segment. Equally important, affordability is a critical factor in achieving equity in transportation by providing reasonably priced vehicles with quality fitting the needs of different users. Keeping in mind that the cost of quality is usually in conflict with affordability, the main challenge during the different phases of the vehicle design and development process from inception to production becomes the achievement of the multi-objective conflicting goals of maximizing affordability and quality at the same time.