Reduce Unique ICDs by Redesigning the Product or the Process

The objective of this activity is to reduce the number of ICDs by reducing the occurrence of an ICD in producing a unit of Output, or by reducing the number of separate ICDs used in the Output. A unique ICD is one of the key activities in the work center's contribution to the final product (O). It is separate and distinct from any other activity in the work center. For example, the fastening of a part onto a subassembly and a quality control check of the subassembly would be unique ICDs.

B. Redesign the process of producing the ICD or Output

Change the process used to produce the ICD or Output to eliminate activities.

4. Reduce movement of an input (People, Purchases or Capital)

Reduce movement of both people and ICDs: Get project participants feedback early to avoid later ICDs:
Busines functions

No. Industry SIC Year Notes
1 2840 1988 P&G usually assigns a packaging engineer to a development group in the earliest stage.
2 3531 1990 Caterpillar reorganized into 13 profit centers based in the plants. At first, it intended to move only design engineers closer to production people. Then it moved marketing and pricing people to the factory, too.
3 3559 1990 Milacron formed a multidisciplinary team with people from purchasing, marketing, inventory, manufacturing, and engineering, to develop a new product.
4 3571 In recent years, IBM has created some 18 special groups throughout the company that link researchers with developers.
5 3571 1988 IBM has also developed "E.M.I." – early manufacturing involvement. Manufacturing people are brought in early to work with the design team.
6 3672 1991 Bell Labs used to set designs at labs then send them to plant for assembly. Now, engineers at both locations work together from the start. Has made production cheaper, easier, and has reduced engineering mistakes.
7 3674 1985 Genus engineered its main product so it could be easily assembled from modules. Designed with subcontracting in mind.
8 3861 1987 Before, finished but unproduceable designs would show up in manufacturing and manufacturing would respond with a hailstorm of requests for design changes. Now, pilot production lines are set up at the prototype stage.

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