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Risk management in Lean Product Development

Lean Product Development features a customer focused and knowledge based approach to eliminate the waste of design reiteration in new product development. Basic Elements of Lean Product Development are introduced first to highlight the process. Risks are managed with tools to anticipate risk, address the risks with robust design, apply accelerated testing and failure analysis to understand limits and weaknesses, and finally track corrective actions to closure. Design Review Based on Failure Modes (DRBFM) and Design Review Based on Test Results (DRBTR) provide risk management tools well suited to Lean Product Development. The origin of DRBFM is found in the Toyota Product Development System with GD3, which are Good Design, Good Discussion and Good Dissection to prevent reliability problems. The method integrates elements of FMEA with elements of design review to identify, verify and correct potential problems. Design Review Based on Test Results (DRBTR) is used to understand the results of testing to failure and correcting product weaknesses. Lastly, the knowledge from DRBFM, accelerated testing and failure analysis is captured for retrieval in a readily accessible tool for use by follow-on product development teams.