Analysis of the product development process to reduce lead time in the engineering sector of a metal-mechanical industry

Goal: This study aims to optimize the product development process (PDP) in the engineering sector of a metal-mechanical industry by applying Lean Manufacturing principles and Value Stream Mapping (VSM) to reduce lead time and improve process efficiency. Design / Methodology / Approach: A case study was conducted using direct observation, data collection, and VSM to map the current state of the PDP. Waste points were identified, and improvement proposals were developed based on Lean principles. A future-state VSM was then proposed to evaluate potential optimizations. Results: Implementing Lean tools led to a 39.13% reduction in lead time and a 15.6% decrease in cycle time, improving overall efficiency by approximately 5%. Process standardization and better information flow also enhanced decision-making and waste reduction. Limitations of the investigation: The study was conducted within a specific industry sector, which may limit the generalizability of the results to other industries with different production characteristics. Moreover, some proposed improvements require further validation through long-term implementation and monitoring. Practical implications: The findings provide actionable insights for industries aiming to streamline their PDP, reduce inefficiencies, and enhance competitiveness by adopting Lean practices. The approach can be adapted to similar manufacturing environments seeking process optimization. Originality / Value: This research contributes to the literature by demonstrating the integration of VSM with PDP in a metal-mechanical industry, providing empirical evidence of its effectiveness in reducing lead time and enhancing process performance. The study highlights the relevance of Lean principles in product development beyond traditional manufacturing settings.