Lean-Driven Innovation: Powering Product Development at the Goodyear Tire & Rubber Company

Lean-Driven Innovation: Powering Product Development at the Goodyear Tire & Rubber Company

By: Norbert Majerus (author), George Taninecz (author)Paperback

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In 2005, Goodyear's research and development (R&D) engine was not performing up to its full potential. The R&D organization developed high-quality tires, but the projects were not always successful. Goodyear embarked on a major initiative to transform its innovation creation processes by learning, understanding, and applying lean product development principles. Within five years, Goodyear saw its product development cycle times slashed by 70 percent, on-time delivery performance rise close to 100 percent, and throughput improve three-fold - all achieved with no increase in the R&D budget. Lean-Driven Innovation: Powering Product Development at The Goodyear Tire & Rubber Company describes in great detail how the Goodyear team was able to achieve such significant improvements. Revealing the ups and downs of this successful transformation, the book shares experiences of how this seismic change was managed, how people were engaged, and how Goodyear dramatically reinvigorated its product development and innovation processes-and, in the process, delivered substantial more value to customers and to the company. The book also explains how lean product development helped Goodyear dramatically improve revenue by having every new product available when the market needed it. Presenting wide-ranging perspectives from all levels of leadership, this book is ideal for anyone in R&D daring to take on a lean initiative in R&D or who is struggling with a lean transformation that is not delivering to its full potential. Since the book focuses on universal lean principles, it is as insightful to other manufacturing and nonmanufacturing disciplines in any industry as well. The book presents invaluable insights gained by the author during his 36 years within Goodyear, of which 10 have been directly involved in trying to develop, implement, and sustain lean to achieve the company's business objectives. It distills ideas, practices, failures, and successes into key principles that lean product development practitioners can easily implement. After reading this book, you will gain a practical path for applying lean to the innovation processes of your organization, including where to begin and what to do, regardless of the industry and the status of your transformation. Watch Norbert Majerus discuss Lean-Driven Innovation at: https://youtu.be/yIlJEMJIcyA

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About Author

Beginning in 2005, Norbert Majerus has implemented a principles-based lean product development process at the three global innovation centers of The Goodyear Tire & Rubber Company, first in Akron, Ohio, and then in Colmar-Berg, Luxembourg, and Hanau, Germany. For nearly a decade, he has been Goodyear's lean champion in research and development. Mr. Majerus, born and raised in Luxembourg, began his career at Goodyear in 1979 with responsibility for materials development, aircraft tires, and competitor benchmarking. In 1983, he moved to Akron to start a "short assignment" in innovative products, which continues to this day. During that time, he was a recipient of discretionary funding for a revolutionary new product and manufacturing process, and he earned more than 60 patents and trade secrets (patentable ideas that the company chose not to patent). Further assignments in Akron have included innovative processes; new tire development and project manager for North American, Asian, and European OEM customers; corporate benchmarking; design and test standards; activity-based R&D accounting; ISO/QS certification; and more. Majerus acquired a six sigma master black belt in 2003 and a lean master black belt in 2005. He holds a master's degree in chemistry from the Universitaet des Saarlandes, Saarbruecken, Germany.


Goodyear Today: Lean Product Development Goodyear Results from Lean Product Development Lean R&D Helps Develop Profitable Value Streams This Lean "Stuff" Really Works Goodyear's Brief History of Lean Product Development Lean Is a Lot of Work Lean Principles Notes Success to Survival to a Foundation for Lean The Golden Age of Tire Technology Early Building Blocks for Lean Use of Product and Process Standards Knowledge Management Office New Business Objectives Note The Beginning of a Lean Process The First Kaikaku-Eroding Profits at Goodyear Change Management Changes for the Worse Policemen, Ambulances, and the Downward Spiral Outside Help Does not Help Out Enough Matrix and Project Management Lean Firsts at Goodyear Notes Finding and Removing Waste from Product Development Focus on the Customer What Do Customers Value? Value and Waste Muda, Muri, and Mura Waste Removal Gets Underway at Goodyear Notes Making New-Product Value Flow Break Down Large Projects into Quick Learning Cycles Early Attempts at Visual Planning Finding Our Bottleneck-Herbie Meets Herbie The Kaikaku We Needed Exploring Pull and Flow Concepts The Turning Point Fast is Better than Slow Create a Kaikaku Pit Crew Tries to Accelerate Speed Notes Lean and Innovation Dispelling Lean Innovation Myths Discovery of Lean Tools in the Innovation Creation Process It Takes More than One Process Create Capacity and Resources for Innovation Funding the Innovation Space Innovation Talent and Serial Innovators Add Room for Failure to the Innovation Space Standardizing Innovation Managing Incoming Work Manage Work Entering the Product Creation Process Cost of Delay (COD) Goodyear COD Calculation Creating Customer Value and Profits Lean Innovation Killers More Innovation than Ever Before Goodyear Innovation Awards Notes Operating the Lean Product Development Factory From Lean Initiative to Lean Function Get the Process Right and Results Will Follow Lean Support-Accounting for Value Responsibility for Quality The End of the Herbie Story-Managing Purpose, Process, and People Lean Purpose Lean Process Lean People Improve R&D Efficiency-It Is OK to be Selfish Lean Expectations and Endurance Notes Lean Never Ends Lean Courage Get Started Notes Index

Product Details

  • publication date: 18/08/2015
  • ISBN13: 9781482259681
  • Format: Paperback
  • Number Of Pages: 493
  • ID: 9781482259681
  • weight: 910
  • ISBN10: 1482259680

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