This research project aims to develop a novel A3 thinking approach to support knowledge driven design that aids the generation of decision making within a Lean Product and Process Development (LeanPPD) environment. This research comprises the development of a new A3 template as a technique of problem solving in product design, the adoption of a reflection practice structured in a new A3 template for knowledge capture and sharing, and the generation of the process of using the A3 thinking approach for effective implementation. Providing useful knowledge as a design reference to generate decision making at the initial stages of product development in product design helps the designers to prevent recurrence of the same problem, eliminate design mistakes and enhance design decision. In order to achieve a novel A3 thinking approach, a research methodology consisting of four phases was developed. The first phase synthesises the A3 best practice through literature and documentation reviews. The gap analysis and results from the reviews have identified several problem-solving approaches and learning cycles that have to be considered in the research. The second phase is to evaluate the approaches and their impacts and applications in product design. In order to complete this, several research methods are selected and performed (e.g. focus group and semistructured interview) within the collaborative companies. The third phase is to develop the A3 thinking approach by utilising the LAMDA learning cycle, developing a new A3 template or so-called A3LAMDA, adopting the reflection practice and generating the process of using the new A3 thinking approach. Finally, the validation of the new A3 thinking approach through industrial case studies and expert judgements have been performed. This approach has been implemented in the automotive sector and was applied to four industrial case studies and six A3LAMDA reports were collected. As a result of the findings of this research, the utilisation of the A3 thinking approach aided the generation of knowledge driven design in product design by integrating the knowledge management capabilities; knowledge creation, capture and sharing.

This research thesis presents the development of a novel Lean Knowledge Life Cycle (LeanKLC) framework to support the transformation into a Lean Product Development (LeanPD) knowledge environment. The LeanKLC framework introduces a baseline model to understand the three dimensions of knowledge management in product development as well as its contextualisation with acclaimed LeanPD process models. The LeanKLC framework comprises 23 tasks, each accomplished in one of the seven key stages, these being: knowledge identification, previous knowledge capture, knowledge representation, knowledge sharing, knowledge integration, knowledge use and provision and dynamic knowledge capture. The rigorous research methodology employed to develop the LeanKLC framework entailed extensive data collection starting with a literature review to highlight the gap in the current body of knowledge. Additionally, industrial field research provides empirical evidence on the current industrial perspectives and challenges in managing product development knowledge. This research was part of a European FP7 project entitled Lean Product and Process Development (LeanPPD), which provided the opportunity to involve industrial collaborators in action research to support practical aspects during the LeanKLC framework development. The synthesis with the current LeanPD paradigm is accomplished by demonstrating the LeanKLC stages in two distinct streams related to the development of A3 thinking for problem solving and the development of trade-off curves to facilitate set based design at the conceptual stage. The novel LeanKLC is validated in two case studies providing the industry with detailed insights on real product development applications. In particular this research highlights that the LeanPD knowledge environment is a wide subject area that has not yet been thoroughly understood and that industry engagement in empirical research is vital in order to realise any form of LeanPD transformation.

Detta examensarbete utfördes inom högskoleingenjörsprogrammet i maskinteknik påKarlstads universitet. Projektet var i samarbete med PLS Produkter AB i Skövde där omställningen på en maskin med namnet Tretapparen analyserades. Maskinen klassas somen multitasking maskin där syftet är tappning av olika typer av flaskor. Problemet är att detsker omställningar ofta då maskinen är flexibel och kan producera många olika typer avprodukter. Omställningarna sker då en ny produkttyp ska tillverkas och är väldigttidskrävande då nya inställningar på maskinen behöver göras. Maskinen och verktygenbehöver dessutom rengöras noga för att inte kontaminera nästa batch. Examensarbetets syfteär att effektivisera omställningen genom att tydliggöra omställningstiderna för maskinensolika moment och bidra med kultur- och kunskapsbyggande till företaget. Målet är att hittamöjliga lösningar som minskar ställtiden på de moment som tar längst tid att ställa om ochdär det kan antas finnas förbättringsmöjligheter. Därmed kan flödet på maskinen förbättras iden mån att antalet tillverkade produkter ökar. Förbättringsarbetet började med förstudier, intervjuer, datainsamlingar och att analyseravideos. All viktig information sammanställdes i en A3-modell där SMED var grunden förstrategierna som gjordes för att ställtidsreducera. Resultatet innebär en konvertering från intern till extern ställtid för varje moment var för sigefter respektive färdig omställning, 26 förbättringsförslag och en ny ordning föromställningsarbetet som tillsammans effektiviserar, standardiserar och planerar upp omställningsprocessen. Efter förändringen minskade omställningstiden med totalt 30%, vilket leder till att flödet påmaskinen förbättras då maskinen kan producera ungefär 217 produkter mer än i dagsläget. Islutet av arbetet gjordes en avrapportering till företaget där samtliga produktionsteam varnärvarande. / This degree project was carried out within the university engineering program in mechanicalengineering at Karlstad University. The project was in collaboration with PLS Produkter AB in Skövde, where the conversion on a machine called Tretapparen was analyzed. The machineis classified as a multitasking machine where the purpose is bottling different types of bottles.The problem is that there are changes often as the machine is flexible and can produce manydifferent types of products. The adjustments take place when a new product type is to bemanufactured and are very time-consuming as new settings on the machine need to be made.The machine and tools also need to be cleaned thoroughly so they do not contaminate thenext batch. The purpose of the degree project is to streamline the adjustment by clarifying theadjustment times for the machine's various steps and contributing cultural and knowledgebuilding to the company. The goal is to find possible solutions that reduce the set-up time onthe steps that take the longest time to adjust and where it can be assumed that there areopportunities for improvement. Thus, the flow on the machine can be improved to the extentthat the number of manufactured products increases. The improvement work began with feasibility studies, interviews, data collection andanalyzing videos. All important information was compiled in an A3-model where SMED wasthe basis for the strategies made to reduce downtime. The result implies conversion from internal to external set-up time for each step separatelyafter each completed conversion, 26 improvement proposals and a new arrangement for theconversion work that together streamlines, standardizes and plans the conversion process. After these changes, the adjustment time decreased by a total of 30%, which leads to animprovement in the flow on the machine as the machine can produce approximately 217products more than at present. At the end of the work, a report was made to the companywhere all production teams were present.

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