LPD could be a lifesaver for seasonal product launches

When time is of the essence, manufacturers may find that a lean product development (LPD) strategy can save the day.

"When the product lifecycle is short, for example, when there's a fad-oriented trend, then speeding up development can be beneficial," says product development consultant Don Reinertsen with Smallpeice Enterprises.

From a food industry perspective, the key aspect of LPD is tightening up the feedback loop, he says. "For example, if your microbiology lab is capable of running 10 tests a week and they have a queue of 150 tests, then it's going to take 15 weeks from when a test is sent in, to when it is running, so a project is sitting idle for 15 weeks."

Instead, he suggests setting an upper limit for tests and, once this is reached, then outsource testing to a trusted firm. "It's extremely important to prevent backlog from generating. Otherwise congestion will have a negative effect on the throughput of the whole system," he says. In addition, he claims that customer enquiries as to where the results have got to will eat into production time.

Although LPD isn't always necessary, it can be vital for products designed for special occasions, such as Christmas or Easter.

"I've worked with a company launching a range of products for the Feast of Ramadan [an event (pictured) where Muslims celebrate the end of fasting by preparing special meals]. Coming close doesn't count - if you miss the celebration, then people won't buy it."

According to Reinertsen, because the primary focus for much of lean manufacturing is the elimination of waste, many companies wrongly assume that this is also the focus of LPD, when in fact the focus is firmly on lifecycle efficiency. "It is only by focusing on flow - not waste - that they can tap into the true potential of LPD."

He is holding a workshop on LPD on March 3-4 in Warwickshire. To find out more contact: Smallpeice Enterprises on 01926 336423.