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The Principles of Product Development Flow: Second Generation Lean Product Development Hardcover – January 1, 2009

4.7 4.7 out of 5 stars 462 ratings

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"...the dominant paradigm for managing product development is wrong. Not just a little wrong, but wrong to its very core." So begins Reinertsen in his meticulous examination of today's product development practices. He carefully explains why invisible and unmanaged queues are the underlying root cause of poor product development performance. He shows why these queues form and how they undermine the speed, quality, and efficiency in product development. Then, he provides a roadmap for changing this. The book provides a well-organized set of 175 underlying principles in eight major areas. He shows you practical methods to: Improve economic decisions Manage queues Reduce batch size Apply WIP constraints Accelerate feedback Manage flows in the presence of variability Decentralize control The Principles of Product Development Flow will forever change the way you think about product development.
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Editorial Reviews

From the Inside Flap

..the dominant paradigm for managing product development is wrong. Not just a little wrong, but wrong to its very core. Today s product development orthodoxy is broken. What s wrong? Companies are pursuing the wrong goals. They maximize capacity utilization, and wonder why cycle times are so long. They strive to conform to plan, and wonder why new obstacles constantly emerge. They try to eliminate variability, and wonder why innovation disappears. They carefully break processes into phases and gates, and wonder why things slow down instead of speeding up. Ironically, each of these actions actually hurts more than it helps.We need a different approach, one based on solid economics and real science. The heart of this approach is FLOW, and the enemy of flow is the invisible and unmeasured queues that undermine all aspects of product development performance. Stagnant piles of idle work lengthen cycle time. At the same time, they delay vital feedback and destroy process efficiency. Yet today, these queues remain unmanaged. Ninety-eight percent of product developers neither measure nor control their queues.But, how can we manage these queues and achieve real flow? It takes a bit of science. We can start with the ideas of lean manufacturing. Then, we must recognize the vast difference between the stable world of repetitive manufacturing and the high-variability world of product development. A product development process must thrive in the presence of variability. Ultimately, we must reach even further, drawing upon ideas from the Internet, transportation systems, computer operating systems, and military doctrine. This is the first book that comprehensively describes the underlying principles that create flow in product development processes, principles that have produced 5x to 10x improvements, even in mature processes. It combines a lucid explanation of the real science behind flow and a rich set of practical methods.Its underlying principles are organized into eight major areas, focusing on practical methods to: Improve economic decisions Manage queues Reduce batch size Apply WIP constraints Accelerate feedback Manage flows in the presence of variability Decentralize control Nobody is better suited to explain these ideas than Don Reinertsen. In 1997, his landmark book, Managing the Design Factory, first introduced the ideas that have become known as lean product development. His two previous books, Developing Products in Half the Time and Managing the Design Factory, have become required reading for all product developers. For over 25 years he has been recognized as a leading thinker on product development issues.This book begins where other books on product development end. It is guaranteed to change the way you think about product development. The Principles of Product Development Flow is destined to become another product development classic.

From the Back Cover

The dominant paradigm for managing product development is wrong; not just a little wrong, but wrong to its very core. Stagnant piles of idle work lengthen cycle time, delay vital feedback and destroy process efficiency. Yet today, these queues remain unmanaged. This landmark book defines a new approach, one based on solid economics and real science. It focuses on controlling the invisible and unmeasured queues that undermine all aspects of product development performance. This is the first book that comprehensively describes the underlying principles that create flow in product development processes, principles that have produced 5 to 10 times improvements, even in mature processes. It combines a detailed explanation of the real science behind flow and a rich set of practical methods. Its 175 underlying principles are organized into eight major areas. It begins where other books on product development end, and is guaranteed to change the way you think about product development.

Product details

  • Publisher ‏ : ‎ Celeritas Pub; 1st edition (January 1, 2009)
  • Language ‏ : ‎ English
  • Hardcover ‏ : ‎ 304 pages
  • ISBN-10 ‏ : ‎ 1935401009
  • ISBN-13 ‏ : ‎ 978-1935401001
  • Item Weight ‏ : ‎ 1.35 pounds
  • Dimensions ‏ : ‎ 6.25 x 1.25 x 9 inches
  • Customer Reviews:
    4.7 4.7 out of 5 stars 462 ratings

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Donald G. Reinertsen
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Customer reviews

4.7 out of 5 stars
4.7 out of 5
462 global ratings

Top reviews from the United States

Reviewed in the United States on June 18, 2014
I got this book on 2014/06/17 and I've read into Chapter 3.

Chapter 1 is somewhat different from the other chapters in that rather than being a series of principles, it provides an overall view of practice orthodoxy and how many of these closely held beliefs are based on secondary or proxy variables. The chapter continues with an overview of several examples and then summarizes and discusses where things are going in the rest of the book as well as the layout. The first chapter is great. I did expect it to end a bit sooner than it did (I was thinking in terms of self-referential, small batch sizes), but I'm not sure a shorter chapter would have been better.

The second chapter introduces the approach for the rest of the book as well as the model underpinning the principles. The approach works for me. I imagine myself reading this book, going back and creating queue cards for each of the principles, then periodically looking up individual ones and refreshing my memory. It seems like a book I can keep going back to and reading just because I want 5 minutes of good reading.

For some context, I'm a software developer. I learned about the Theory of Constraints (ToC) before I really learned software development processes in depth. When I did being the software process journey, it was under the OO umbrella, so incremental and iterative, feedback, etc. This learning, however, I've recently realized (by first reading Kanban and now this book) was heavily influenced by the ToC. At the beginning of this century, I jumped on the XP and Scrum bandwagons, even working with a few of the original signatories on the manifesto for agile development.

ToC came up a number of times while coaching. Moving from ToC to thinking in terms of Kanban isn't much of a leap to me. However, since I was applying things I learned and internalized, things that seem obvious to me are often not obvious to my customers or even my colleagues (yes, sometimes I'm wrong, but often I'm not). For example, at many, many places I've been, companies claim they are practicing continuous integration or even continuous delivery, but then their builds are broken (red) 80+ % of the time. This is a huge cost to productivity, morale, feedback, etc. This is one example of many such examples that, in in the context of ToC are obvious bottlenecks, which cause queueing. If I look with lean glasses, many of these are worthy of stopping the line, but people march on, building up queues of work to be committed, which lead to more broken builds, integration problems, demoralization, etc.

However, what seems obvious to me doesn't seem obvious to others. More importantly, many people don't even see that there's a problem at all! They think, for example, when developers complain about being blocked due to the build being broken, it's just developers complaining about a minor glitch, but it is more typically a systemic problem.

This books presents a model based on economics. One thing that I observed myself observing about the book was that I thought it might be over emphasizing one dimension, cost of delay, or one approach, economics. However, "all models are wrong, some are valuable." While I had this observation, I didn't find anything wrong about the conclusions, and in fact find my self thinking "yes and," so I've kept reading. So while this model may be wrong in some ways (I'm not aware of any), I clearly see immediate and near-term value for me with its use.

What this model does is allow me to speak to upper management, and maybe middle management using a language they are likely to appreciate. I'm able to justify things like slack using economic models, so that I might be better able to communicate with them. So rather than talking about the flexibility and agility that well under 100% utilization might offer, instead I can discuss the cost of delivery related to high utilization (lack of slack). My primary failing up until now is not being able to explain what seems intuitive to me in a way that bridges the communication gap. This model seems to give me another way to both think about it and communicate it.

I have not finished reading the book, but in the the spirit of small batch sizes, this is my first delivery. I'll be making updates as I read the book. I am already confident that I'll finish this book and that I can recommend it to people. It'll have to really work hard to go under a 5 star review.

Finally (so far): my impression so far reading the book is that it seems well researched, brings together a number of disciplines in a non-trivial manner and seems to come form someone who legitimately has many good years of experience, not just the same 1 year of experience repeated over and over.
26 people found this helpful
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Reviewed in the United States on May 26, 2011
Donald Reinertsen's latest book on new product development aspires to making a global and historical impact. He systematically applies the theory and best practices of lean manufacturing, economics, queuing theory, statistics, web communications, operating systems, control engineering and military science to the new product development process. He summarizes these insights in 8 themes and 175 principles. Examples and graphs illustrate the concepts.

This is a dense book. The target audience of marketing MBA's, industrial engineers, project and general managers will be challenged. It requires some familiarity with lean manufacturing, economics and operations research. The principles are illustrated but not obvious. The quality, lean manufacturing, Toyota Production System, theory of constraints and technical sources are briefly referenced. The rationale for existing (stage-gate) best practices is not explained. Limits and trade-offs are not discussed.

Nonetheless, this is an audacious and path breaking book. Product development practitioners can learn and apply the principles of this book.
Economics trumps simple versions of quality paradigms. Expected net lifetime value is king. Marginal cost/benefit analysis rules. Global optimums outweigh local ones. Proxy measures undermine optimal economic decision-making. Decisions matter, precision does not. Priority features/competitive advantages matter most. Economic rules of thumb allow decentralized decisions. Cost of delay is managed through an explicit value of time.

Queuing theory manages delays. Project and task cycle times drive the cost of delay. Long queues increase defects, variability and risks. Misplaced high efficiency and utilization goals lead to delays, increased costs and disastrous momentum. Communications links between adjacent processes matter more than bottleneck capacity. Simple views that delays, variability, inventory or waste are evil or have infinite cost lead to bad decisions. Queues are everywhere in product development.

Measure variability with a payoff function. It can be negative or positive. Testing generates information value. Statistics based steps reduce variation, such as smaller tasks and time horizons. Counterbalance and design reuse offset variability. Economic priorities, faster iterations and early high risk actions minimize the impact of variability.
Smaller task batch sizes reduce variability and cycle time, accelerate feedback, improve engagement and reduce risk and overhead. Large batches increase costs, delay progress and may spin out of control. Optimum batch sizes are small and can be found through trial and error. Combine features in separately developed and tested modules. Smaller batches are more beneficial than capacity increases. Large batches impact every step of product development.

Detailed planning and control of tasks is costly. It is more effective to control the work in process between major functions. As with TPS or Theory of Constraints, managing the flow of released product from stage to stage improves final results. Many scheduling, prioritization, resource and recovery strategies can minimize task WIP. A blended generalist/specialist staff skills profile offers flexible capacity.

The flow of activities through product development can be managed. Use forecasts and share information between adjacent stages. Use cadence to set routine start/stop times. Synchronize tasks so that dependent events flow smoothly. Sequence tasks and change priorities based upon risk and incremental economic value added. Build in flexible paths and spare resources.

Develop rapid feedback systems. Employ early warning systems and value at risk triggers to escalate reviews. Align activities through training, incentives and templates. Adjust decisively when required. Use frequent communication to build teams and short queues to build urgency. Employ flow metrics.

Decentralize decision making to speed the flow and avoid management bottlenecks. Provide high level structure in the form of rough-cut plans, rules of thumb, intentions, templates and sequences.

The principles in this book can be applied to any operations or development process. The value added is limited only by the time invested.
8 people found this helpful
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Reviewed in the United States on January 4, 2015
It is a comprehensive set of "rules" to consider when designing your Product development flow, and to many there are true surprises and eye openers. It is mostly - as I see it - the same rules and ideas (and a few additions) as in the famous "Managing the Design Factory" book, but here it is organized more like a rules book with a long list of rules to go through and check for. It is a tough book to read from end to end (not sure that it is actually the intention). However the first 2-3 chapters which are more "normal" will alone justify purchasing this great book. (I did like the managing the design factory better though, because it was easier to read I think).

Top reviews from other countries

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Christoph Dibbern
5.0 out of 5 stars Groundbreaking book about fostering the right balance between efficiency, effectiveness and predictability
Reviewed in Germany on September 22, 2023
“Using Fast Feedback: A little rudder early is better than a lot of rudder late.“

The author incubates lean and agile principles to foster fast feedback and learning to maximize the value for the customer, while minimizing the risks.

One of the highlights of the book is stressing the advantages of decentralized control for tactical and customer-centric decision, while highlighting also the necessity of centralized, infrequent decision with strategically overall relevance.

Amazing read!
Barbara Schultz
5.0 out of 5 stars What an awesome way to speak the language of business ($$) in order to promote business agility.
Reviewed in Canada on March 1, 2021
As an agilist, I know the impact of queues in manufacturing but we often have trouble selling counter-intuitive agile concepts to senior management. This book when applied to agility will allow us to speak their language and frame the benefits in terms of profitability by speaking their language and doing the math that they depend on so readily.
DT
5.0 out of 5 stars Revolutionary Thoughts on Product Development Management in Bite-size chunks
Reviewed in the United Kingdom on July 26, 2020
I am humbled by the wealth of intellectual thought and pragmatic guidance contained in this easily accessible book by Mr. Reinertsen. His language and layout choices have made it easy even for a Neanderthal such as me to grasp the depth of his thought. He combines academic rigour with simple advice on how to apply the theories in a workplace. In one book he exorcises the superstitions that have led to manufacturing management methods being mis-applied to the very different realm of product development

175 principles to establish or boost the flow of product development by focussing decision-making on economic benefit. Each principle is defined in clear language and then practical examples are used to demonstrate how to apply in your workplace.

As an engineering manager and director, this book has become a guiding light that I return to on a regular basis to mine the gems that Mr. Reinertsen has gathered together.

If you are involved in the management of Product Development teams, this book should be bought, devoured and absorbed into your DNA. Anything less is irresponsible.
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Riccardo Ianniello
5.0 out of 5 stars Uno dei migliori libri sul product management
Reviewed in Italy on December 27, 2018
Non è un libro semplice, per quanto l'autore si sia sforzato di ridurre al minimo i dettagli matematici.
Fatta questa premessa, si tratta di uno dei migliori libri sull'argomento. L'autore offre una serie di principi ispirati a diverse discipline (dalla matematica, alla statistica, dal lean thinking, alla teoria delle cose, alla strategia militare) e applicati allo sviluppo di prodotti, grazie ai quali mette in discussione il pensiero "ortodosso" e offre nuove prospettive.
Prakash Goteti
5.0 out of 5 stars Excellent work by Reinertsen
Reviewed in India on March 5, 2017
The principles are quite interesting and useful both in the perspective of product development and understanding SAFe Cadence
One person found this helpful
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