The Mastery of Innovation: A Field Guide to Lean Product Development, 1st Edition (Hardback) book cover

The Mastery of Innovation

A Field Guide to Lean Product Development, 1st Edition

By Katherine Radeka

Productivity Press

265 pages | 38 B/W Illus.

Shingo Award Winner
Purchasing Options:$ = USD
Hardback: 9781439877029
pub: 2012-10-11
eBook (VitalSource) : 9780429251665
pub: 2012-10-11
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What do Ford Motor Company, Steelcase, Scania, Goodyear, Novo Nordisk, and Philips Electronics have in common? They all need to get their best ideas to market as fast as possible. They need to achieve the mastery of innovation.

When these companies needed to accelerate time-to-market, get more new products to customers, and improve their ROI from investments in R&D, they turned to Lean Product Development to help them master the process of innovation. By adapting Lean ideas to their specific product development challenges, they learned how to focus innovation on the problems that would maximize customer and business value, and deliver on their best ideas.

Winner of a Shingo Research and Professional Publication Award!

The Mastery of Innovation: A Field Guide to Lean Product Development describes the experiences of 19 companies that have achieved significant results from Lean Product Development. Their stories show that Lean Product Development delivers results:

  • Ford Motor Company completely reinvented its Global Product Development System and put decades of knowledge about automotive design at its engineers’ fingertips
  • DJO Global, a medical device company, more than tripled the number of products they released to the market and cut development time by 60%
  • Playworld Systems cut time-to-market in half–twice

The diverse set of North American and European case studies in this book range from very small product development organizations (three engineers) to very large (more than 10,000). Some of the industries represented include automotive, medical devices, industrial products, consumer electronics, pharmaceuticals, scientific instruments, and aerospace.

These companies have generously shared their knowledge about Lean Product Development to help you get your best ideas to market faster.

Table of Contents


Lean Product Development: The Mastery of Innovation

The Definition of Lean Product Development

We Already Do All of This—Have We Mastered Innovation?

How Does Lean Product Development Deliver Results?

The Engine of Knowledge Creation

Value and Waste in Product Development

Value-Creating Activities and Waste

Value and Waste in Product Development

The Four Value Streams of Lean Product Development

The Lean Product Development Benchmarking Study

Where Did These Companies Come from?

A Diverse Set of Companies

What Surprised Me

Suggestions for Using the Case Studies


DJO Global: The Fundamentals of Lean Product Development

Lean Product Development at DJO


LAMDA and A3 Problem Solving in Product Development

Metrics to Drive a Lean Product Development Culture

Results and Next Steps

Scania Technical Centre: A Pioneering Lean Product Development Champion

Lean Product Development at Scania

Lean Improvement Coaches

Product Development Team Engagement

Product Development Leadership at Scania

Visual Planning

Ford Motor Company: How to Revitalize an American Icon

Lean Product Development at Ford

The Chief Engineer

Example: Reducing Wind Noise

Results and Next Steps


Buckeye Technologies: Lean Tools for Strategic Alignment

Lean Product Development at Buckeye

Systematic Problem Solving for Product Strategy Development

The Power of Pull Factors

Lean Ideation with Convergence

Results and Next Steps

Steelcase: Go-and-See New Customers to Open New Markets

Lean Product Development at Steelcase

Customer Intimacy Intelligence in Action


Value and Price Validation

Value-Driven Design


Philips: Comprehensive Lean Scheduling

Lean Product Development at Philips Consumer Lifestyle

Lean Scheduling

Team-Based Planning Process

Status Updates

Results and Next Steps


Novo Nordisk: Metrics to Drive Change

cLEAN®: Lean at Novo Nordisk

The Interpretation of Lean at Novo Nordisk R & D: Six Basic Principles

Transactional versus Knowledge Creation Processes

Critical Questions Mapping

Keeping Progress Visible: Metrics and KPIs

Results and Next Steps

Visteon: Knowledge at the Engineer’s Fingertips

Lean Product Development at Visteon

Simple Process Models

Lean Process Audits

Reusable Knowledge

Results and Next Steps

A-dec: Project Chiefs to Speed Decision Making

Lean Product Development at A-dec

First Step: Team Leadership

The Project Chief

Product Development Organizational Structure

Go-and-See Customer Visits

Results and Next Steps


Nielsen-Kellerman: Just Start Somewhere

Lean Product Development at Nielsen Kellerman

Inefficient Meetings: Visual Project Planning

Knowledge Capture and Retrieval: The Knowledge Library

Nielsen-Kellerman’s Product Development Process

Systematic Problem Solving to Solve Technical Problems


Vaisala: From Pilot Projects to Global Transformation

Lean Product Development at Vaisala

Vaisala’s Countermeasure for Travel Expense Allocation

Product Portfolio Management

Widespread Training

Vaisala’s Next Steps

Playworld Systems: How to Cut Time to Market in Half—Twice

The Need for Speed and Predictability

First Attempts with Lean Thinking in Product Development

Lean Product Development at Playworld

Cutting Time to Market in Half—Twice

What’s Next for Playworld?


The Path of Mastery: How to Begin with Lean Product Development

How Long Will It Take?

The Phases of Lean Transformation

Start Wherever You Are

Epilogue: Just Start Somewhere, Just Do Something

Appendix 1: The Mastery of Innovation Self-Assessment

Appendix 2: A Guide for Book Study Groups

Appendix 3: List of Participating Companies

Appendix 4: Suggested Reading List and Other Resources


About the Author

Katherine Radeka has a rare combination of business acumen, scientific depth, and the ability to untangle the organizational knots and remove the barriers to change. In the past seven years, her consulting firm, Whittier Consulting Group, Inc., has engaged with clients such as Steelcase, Hewlett- Packard, and more than 50 other leading organizations.

In 2010 and 2011, Katherine conducted the Lean Product Development Benchmarking Study to document Lean Product Development practices at more than 60 companies in North America and Europe. In 2005, she logged more than 11,000 miles driving around the country to research how the best companies got more ROI from product development. In 2007, she co-founded the Lean Product & Process Development Exchange, a nonprofit organization to promote the use of Lean Thinking to improve ROI from product development.

Katherine has climbed seven of the tallest peaks in the Cascade Mountains and spent 10 days alone on the Pacific Crest Trail until an encounter with a bear convinced her that she needed a change in strategic direction.

Subject Categories

BISAC Subject Codes/Headings:
BUSINESS & ECONOMICS / Quality Control
BUSINESS & ECONOMICS / Industries / Manufacturing Industries