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Sunday, December 11, 2011

LEAN FUNCTION DEPLOYMENT (LFD): DETERMINING THE LEAN IMPLEMENTATION POINT USING A CUSTOMER PERSPECTIVE

By Amy Bugyis
IE 401 Integrated Manufacturing, University of Tennessee

Abstract
Lean Function Deployment (LFD) was developed to fill the need for a method that determines the lean implementation point using customer needs in determining process steps. LFD is a method developed by combining the
underlying principles of Quality Function Deployment (QFD) and existing lean methods to detect where to implement lean in a process. The LFD methodology is an algorithm using paired comparison and relative rankings between needs, technical characteristics, process parameters, and process steps using input from both the customer and the process engineer. LFD determines the critical-to-quality (CTQ) and the critical to lead-time process steps in the production of a product using 2 phases. LFD ultimately mitigates the problems of QFD by using a consistent and defined ranking system to quantify results. LFD uses a weighting system that connects expected weights for each step of the algorithm. Ultimately, the customer need rankings are tied to the final CTQ process ratings by carrying weights between sub-phases.
The effectiveness of the LFD tool was tested among subjects and proved to increase the distinction between ratings for process parameters because it has a decreased range in rankings among subjects. Finally, a computer program was developed and is available on a Web site to show the real-world application of the proposed lean implementation tool.



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