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Design for Lean: Building flow and eliminating waste from the very beginning

Discover how embedding Lean principles in the design phase can reduce costs, eliminate waste, and accelerate time-to-market. This deck by BMGI India explores why Design for Lean matters, its core principles, common sources of waste, and practical tools like VSM, DFSS, TRIZ, and FMEA. Featuring a real FMCG case study, it highlights the measurable benefits of Lean-driven design and how BMGI India helps organizations build smarter, scalable, and efficient systems right from the start.<br><br>https://www.bmgindia.com/innovations/design-for-lean

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Design for Lean: Building flow and eliminating waste from the very beginning

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  1. Design For Lean:Building Flow & Eliminating Waste From The Very Beginning BMGI India | Operational Excellence & Innovation Consulting www.bmgindia.com

  2. Why Design for Lean Matters • 70–80% of lifecycle costs are determined in the design phase • Poorly designed workflows lead to inefficiency, rework, and higher costs later • Embedding Lean principles in design ensures processes are right the first time • Early elimination of waste improves speed, quality, and margin

  3. Principles of Design for Lean Focus on Value as defined by the customer Build Flow across the end-to-end design process Remove waste early before it reaches production or operations Create flexibility and scalability in processes and systems Ensure alignment between customer, process, people, and finance outcomes

  4. Typical Sources of Waste in Design Over-engineering and unnecessary complexity Excess iterations and rework Delays in approvals or handoffs Poor knowledge transfer between functions Inadequate consideration of manufacturability or serviceability

  5. Value Stream Mapping (VSM): Identify bottlenecks in the design process Design for Six Sigma (DFSS): Build quality into the design stage TRIZ methodology: Resolve contradictions systematically Failure Mode and Effects Analysis (FMEA): Prevent defects early Workflow management tools: Standardize and streamline design steps Tools for Design for Lean

  6. Reduced development cycle time Fewer defects and shorter correction loops Lower cost of poor quality Improved first pass yield in production Faster time-to-market with reliable performance Sustainable capacity optimization Benefits of Applying Design for Lean

  7. Case Example FMCG Packaging Redesign • Problem: High material cost and frequent design rework • Approach: Applied Value Stream Mapping and DFSS during the design stage • Outcome: Reduced packaging material use by 12% and design cycle time by 20% while improving durability

  8. BMGI India’s Role in Design for Lean Recognized Design for Lean consulting company in India Expertise in Lean, Six Sigma, TRIZ, and DFSS Customized frameworks for FMCG, pharma, manufacturing, and energy Hands-on management training courses to build internal capability Proven success in embedding process excellence from the design phase

  9. Takeaway Design phase is the best place to remove waste and build efficiency Lean principles create flow and align teams early BMGI India helps organizations design smarter, execute faster, and sustain results

  10. Breakthrough Management Group India Private Limited Location: 905/906 Raheja Chambers, 213 Nariman Point, Mumbai, Pin-400021, India Phone: +91 22 4002 0045/46 | Email: info@bmgindia.com

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