| Preface to the English Edition |
| Preface to Japanese language Edition (1997) |
| I. Problem Areas in Existing Thinking Methodology and Management Methodology |
| II. What are the characteristics of the thinking and procedures appearing in this book? |
| III. How the Japanese version of this book was published |
| IV. The Application and Structure of this book |
| V. The Pupose Measure Relationship of the DTCN/DTC Methodology |
| Acknowledgements (1984, 1997, 2001) |
| Prologue (A Way Of Thinking And Recognition) 1 |
| 1.1 Introduction 4 |
| 1.1.1 The Birth of the Methodology And Its Background 4 |
| 1.1.2 The purpose of the methodology 5 |
| 1.1.3 Scope of the methodology 11 |
| 1.1.4 The structure of the book 12 |
| 1.2 Decision Mechanism using Information of Difference 23 |
| 1.2.1 Introduction 23 |
| 1.2.2 Decision-making in a simple example 24 |
| 1.2.3 How to create a Purpose-Measure Diagram, which shows the direction of value for decision-making 25 |
| 1.2.4 Necessary conditions for making decisions in management 28 |
| 1.2.5 Persuasive Forecast 30 |
| 1.2.6 A Method for easily identifying the information of difference 31 |
| 1.2.7 Card-making for comparing information 32 |
| 1.2.8 Purpose-Method Diagram for the maintenance of standard man-hours 33 |
| 1.2.9 Summary 33 |
| 1.3 Proper Use of Questioning for Creative Thinking and Decision-Making - Effective Use of the Questions "In order to do what?", "How to do?" and "Why" - 46 |
| 1.3.1 Understanding the difference between the questions "In order to do what?" "How to do?" and "Why?" 46 |
| 1.3.2 Proper use of the questions "In order to do what?" "How to do?" and "Why?" 46 |
| 1.3.3 Proper use of "Why?" questin 47 |
| 1.3.4 The "because" theory 48 |
| 1.3.5 The effect and evaluation of the methodology 49 |
| 1.4 Way of Thinking and Policy of DTCN/DTC 52 |
| Chapter 2 Seven Basic Methods of DTCN 53 |
| 2.1 PMD (Purpose-Measure Diagram) Method to Clarify the Relationship between Purpose and Measures (alias the Method of Key Word) 58 |
| 2.1.1 Introduction 58 |
| 2.1.2 Procedure 58 |
| 2.1.3 Supplementary notes 60 |
| 2.1.4 Examples 61 |
| 2.1.5 Considerations 62 |
| 2.1.6 Theme PMD Method (Method of Theme Key Word) 62 |
| Episode 1 PMD Method and nodding when trying to understand something 67 |
| Episode 2 Using the the PMD Method can be used to investigate language 70 |
| Episode 3 PMD Method can clarify "chicken or egg?" relationships 72 |
| Episode 4 The Method of Key Question 74 |
| 2.2 Steplist Management Method to Create a Faultless Phased Procedure 76 |
| 2.2.1 Introduction 76 |
| 2.2.2 Explanation of the Steplist format 76 |
| 2.2.3 The procedure to make a Steplist, and how to use it 77 |
| 2.2.4 Supplementary notes 78 |
| 2.2.5 Examples 79 |
| 2.2.6 Considerations 80 |
| 2.2.7 Functions of Steplist management 81 |
| 2.2.8 Significance of Steplist management 83 |
| 2.2.9 Acknowledgments 83 |
| 2.3 3-5(Three-Five) Phase Improvement Method to Divide the Approach to Improve Anything from its Present Status 93 |
| 2.3.1 Introduction 93 |
| 2.3.2 Procedures 94 |
| 2.3.3 Supplementary notes 94 |
| 2.3.4 Considerations 95 |
| 2.4 FBS (Function Breakdown Structure) Technique to Create the Image Structure 98 |
| 2.4.1 Introduction 98 |
| 2.4.2 Explanation of the method using examples 98 |
| 2.4.3 Method for creating the most appropriate expression of the basic function (Key Word) 100 |
| 2.4.4 How we can come up with effective ideas, and compare and select from them 101 |
| 2.4.5 How we should create, compare, and select Breakdown Structures 102 |
| 2.4.6 Extended use of Breakdown Structures 104 |
| 2.4.7 Using this method to improve existing products, and to develop new products and new markets 106 |
| 2.4.8 Considerations 106 |
| Episode 5 The relationship between PMD, Steplist, FBS, and 3-5 Phase Improvement 115 |
| Episode 6 Accumulation of Knowledge and Wisdom 117 |
| 2.5 WBS Theme Phasing Technique to Gather Themes and Ideas from the People Concerned and Examine Them in a Timely Manner 119 |
| 2.5.1 Introduction 119 |
| 2.5.2 Procedures 120 |
| 2.5.3 Supplementary notes 121 |
| 2.5.4 Considerations 122 |
| Episode 7 Differences in the way of men and women think 129 |
| Episode 8 A Strange phenomenon in visual recognition: a difference between men and women 136 |
| Episode 9 The difference between men and women in dextro-rotation and levo-rotation 141 |
| 2.6 Root Organizing Method to Start New Things in Existing Organizations 144 |
| 2.6.1 Introduction 144 |
| 2.6.2 Procedures 145 |
| 2.6.3 Supplementary notes 146 |
| 2.6.4 Considerations 147 |
| 2.7 Implementation Plan Document Method to Materialize the Objective Result of the Organization 150 |
| 2.7.1 Introduction 150 |
| 2.7.2 Procedures 150 |
| 2.7.3 Supplementary notes 151 |
| 2.7.4 Use of the implementation table format 153 |
| 2.7.5 Considerations 153 |
| 2.8 How the DTCN Methodology was Created and a Comparison of the Steplist Procedure with Conventional Procedures 157 |
| 2.8.1 Introduction 157 |
| 2.8.2 How the DTCN methodology was created 157 |
| 2.8.3 Considerations 159 |
| Chapter 3 Examples of the Application of the Basic Method and their Considerations 167 |
| 3.1 How to Create the Domains of Thinking and Consensus among the People Concerned (the Details of the PMD Method and Advanced Considerations) 170 |
| 3.1.1 Introduction 170 |
| 3.1.2 Purpose of the Chapter 171 |
| 3.1.3 Definition of Terms 171 |
| 3.1.4 The Need for a New Method as Felt When Preparing Preliminary and Follow-up Research and Development Plans in the Conventional Way 172 |
| 3.1.5 Structure of the Chapter 174 |
| 3.1.6 Basic Principles of the Application of the Method 174 |
| 3.1.7 Specific Examples 174 |
| 3.1.8 The Basic Model of the PMD Method and Variations on the Model 177 |
| 3.1.9 Further Considerations 182 |
| 3.1.10 Future Perspectives (as of 1992) 195 |
| Episode 10 Avoiding Confusion between the Terms "Problem" and "Theme/Subject" 219 |
| 3.2 The Details of the Steplist Method and Advanced Analysis 222 |
| 3.2.1 Introduction 222 |
| 3.2.2 Specific Examples of Steplists in an Airplane Development Project 222 |
| 3.2.3 Steplists at the Integrated System Level 223 |
| 3.2.4 Steplists at the Equipment Specifications Level 224 |
| 3.2.5 Steplists at the Equipment Vendor Level 224 |
| 3.2.6 Reciprocal Relationships between the Three Steplists 224 |
| 3.2.7 Considerations 224 |
| Chapter 4 Supplemental methods for DTCN methodology 241 |
| 4.1 WBS Method (Re-definition) 245 |
| 4.1.1 Introduction 245 |
| 4.1.2 What is WBS? 245 |
| 4.1.3 WBS in the wider sense 246 |
| 4.1.4 How to prepare a parent-child-style WBS (WBS method) 247 |
| 4.1.5 Software to input the above results (this product was prepared by the author) 247 |
| 4.1.6 Discussion 248 |
| Episode 11. Effects of two styles of WBS, lateral sentence-connecting and vertical parent-child, on the balance of contents and the prevention of "missing items" or "faulty items" 255 |
| 4.2 WBS in Moebius style to effectively and efficiently allocate design work in the beginning stages of Design (Moebius strip-style WBS) 257 |
| 4.2.1 Introduction 257 |
| 4.2.2 What is a Moebius strip-style WBS? 257 |
| 4.2.3 Overall flow of the Moebius strip-style WBS 258 |
| 4.2.4 How to spread a Moebius strip-style WBS 258 |
| 4.2.5 Detailed interface between WBSs 260 |
| 4.2.6 Discussion 261 |
| 4.3 Evaluation and structuring method for pre-evaluation from a rational perspective 268 |
| 4.3.1 Introduction 268 |
| 4.3.2 What is the pre-evaluation method? 268 |
| 4.3.3 Priority Method 269 |
| 4.3.4 Scoring Method (revised) (Table 4.3-2) 269 |
| 4.3.5 DARE (Decision Alternative Ratio Evaluation) Method 270 |
| 4.3.6 Considerations in scoring the evaluation 271 |
| 4.3.7 Rules for taking a reasonable majority decision on evaluation plans 271 |
| 4.3.8 Method to immediately combine and select the best structuring plans 272 |
| 4.3.9 Essentials for evaluation-based decision-making 272 |
| 4.3.10 Discussion 273 |
| Episode 12 Meaning of Evaluation, and Interpretation of Evaluation Criteria 280 |
| Episode 13 Contents of the terms, "abduction," "verification," "evaluation," and "decision-making" 283 |
| Chapter 5. Reasonable Purchase Price and the Criteria for its Determination (Knowledge of Reasonable Purchase Price) 291 |
| 5.1 Steplist for a reasonable purchase price 294 |
| 5.1.1 Introduction 294 |
| 5.1.2 Viewpoints for preventing personal loss 295 |
| 5.1.3 The way of thinking for a reasonable purchase price 296 |
| 5.1.4 Steplist for a reasonable purchase price 297 |
| 5.1.5 Discussion 298 |
| 5.2 How to use a price/cost breakdown table for cost control 304 |
| 5.2.1 Introduction 304 |
| 5.2.2 What is a price/cost breakdown table? 304 |
| 5.2.3 Price/cost breakdown table to understand cost 304 |
| 5.2.4 Price/cost breakdown table to provide room for cost control 308 |
| 5.2.5 Discussion 310 |
| 5.3 Price Determination Criteria 318 |
| 5.3.1 Introduction 318 |
| 5.3.2 Pricing principles 318 |
| 5.3.3 Purchase price policy and the overall adjustment factors for the policy 319 |
| 5.3.4 Types of prices 320 |
| 5.3.5 Viewpoints required for a purchase price policy 323 |
| 5.3.6 Purchase price patterns and the factors to change them 324 |
| 5.3.7 Purchase market investigation 325 |
| 5.3.8 Technical purchasing ability 326 |
| 5.3.9 Discussion 327 |
| Chapter 6 Basic Conditions to Proceed with "Design to Cost" 329 |
| 6.1 General Matters 332 |
| 6.1.1 Introduction 332 |
| 6.1.2 Effect of Combining DTC Method Using Development Control with the DTCN Method 334 |
| 6.1.3 Discussion of Conventional DTC 335 |
| 6.2 Minimum Knowledge Needed to Proceed with Design to Cost 338 |
| 6.2.1 Decision-Making Based on Creation of Information of Difference 338 |
| 6.2.2 Cost Driving Factor 338 |
| 6.2.3 Grade of Estimate 339 |
| 6.2.4 Recognize Differences among DTCs for Mass Production Unit Cost, Development Cost, and Lifecycle Cost 340 |
| 6.2.5 Difference Between Development Step Portion Which Implements DTC and Development Step Portion Which Does Not Implement DTC 343 |
| 6.3 Essential Conditions to Proceed with Design to Cost 352 |
| 6.3.1 Securing or Dividing the DTC Implementation Budget 352 |
| 6.3.2 Preparation of a DTC Implementation Plan Document Using the DTC Method and an Effective Follow-up Utilizing Questionnaire Prepared in Advance 353 |
| 6.3.3 Preparation of Necessary Cost Verification Guidelines (Needed Especially for Contracts with the Government) 354 |
| 6.3.4 Confirming the Existence of the Basic Agreement of Materials Transaction Among Corporations 355 |
| Episode 14 Risk Management 362 |
| Chapter 7 Design to Cost (DTC) for Unit Production Cost 363 |
| 7.1 General Matters 367 |
| 7.1.1 Introduction 367 |
| 7.1.2 Outline: DTC Steplist and Each Step for Unit Production Cost 368 |
| 7.2 Details of Each DTC Phase 376 |
| 7.2.1 DTC Preparation (DTC Phase I) 376 |
| 7.2.2 Allocation of DTC Target Cost (DTC Phase II) 378 |
| 7.2.3 Basic Design Work Using DTC Worksheet (Preparation of Plan Drawing)(DTC Phase III) 381 |
| 7.2.4 Detailed Design Work Considering Cost-Driving Factors (Preparation of Manufacturing Drawing) (DTC Phase IV) 388 |
| 7.2.5 Prototype Production and Qualification Test (DTC Phase V) 391 |
| 7.2.6 Review Before Mass-Production (DTC Phase VI) 392 |
| 7.3 Comparison of Purchase Parts and Selection by DTC Procedure 409 |
| 7.3.1 First Information Collection Phase 409 |
| 7.3.2 Basic Concept Comparison Phase 410 |
| 7.3.3 Breakdown and Combination Phase 410 |
| 7.3.4 Second Information Collection Phase 410 |
| 7.3.5 Vendor Selection Phase 411 |
| 7.3.6 How to Guide Vendors to Implement DTC Activities 412 |
| 7.4 DTC Implementation for Lifecycle Cost Using Information of Difference 431 |
| 7.4.1 What is Lifecycle Cost Design? 431 |
| 7.4.2 Lifecycle Cost Design using Information of Differences 431 |
| 7.5 Setting up the Organization and Management for DTC Works 435 |
| 7.5.1 Input 435 |
| 7.5.2 DTC Work Activities (Assurance Activity Prior to the Output) 438 |
| 7.5.3 Output 438 |
| 7.5.4 Adjustment and Confirmation of DTC Results (Post-Assurance Activity) 439 |
| 7.6 Significance of Thinking and Procedures for DTC using DTCN Method 447 |
| 7.6.1 Significance of Thinking and Procedures for DTC Using DTCN Method 447 |
| 7.6.2 Conclusion 448 |
| Chapter 8 Design to Cost for Development Costs 453 |
| 8.1 General Matters 456 |
| 8.1.1 Introduction 456 |
| 8.1.2 Review of the difference between DTC for unit production costs, DTC for lifecycle costs, and DTC for development costs 456 |
| 8.2 Basic Matters 462 |
| 8.2.1 Basic principles 462 |
| 8.2.2 Phase division of ordinary development activity 462 |
| 8.2.3 Concrete phase division to implement DTC for development costs 462 |
| 8.2.4 Key to implementing DTC for development costs 464 |
| 8.2.5 PMD (Purpose-Measure Diagram) for development activity 466 |
| 8.2.6 Two-page plan and estimate of development activity 467 |
| 8.3 Q＆A about DTC for Development Costs 475 |
| 8.4 Cost status report on DTC for development costs 486 |
| 8.4.1 How to make the cost status report 847 |
| 8.4.2 Relation between DTC cost status line and PMD of development activities 847 |
| 8.5 Unexpected cost classification and management method in implementing DTC for development cost 489 |
| 8.5.1 Unexpected cost classification and management method (draft) 489 |
| 8.6 Significance of DTC for development cost by DTCN methodology 502 |
| 8.6.1 Current status of DTC for development costs in the United States (as of 1991) 502 |
| 8.6.2 Current status of DTC for development costs in Japan (as of 1991) 502 |
| 8.6.3 Significance of DTC for development cost by DTCN methodology in this book 503 |
| Chapter 9 Conclusions and Future Perspectives 505 |
| 9.1 Conclusions 508 |
| 9.1.1 Significance of this Publication 508 |
| 9.1.2 Answers to Challenges that Revealed the Need for this Publication 508 |
| 9.1.3 Other Points Made Clear and Feasible through this Publication 516 |
| 9.1.4 Practical Outcomes 517 |
| 9.1.5 Further Applications of the Methods Found in this Publication 518 |
| 9.2 Future Perspectives and Challenges 523 |
| 9.2.1 Consolidation of Existing Concepts into Further Supplemental Applications (Structured Procedures and Images) 523 |
| 9.2.2 Actual Application of the DTCN Method in a Report concerning Proposal No. 19, "Basic Research Plan for Software-Related Technology" of the Science and Technology Committee of the Japanese Government Dated Dec. 12,1992[3] 524 |
| Acknowledgments regarding the Doctoral Dissertation |
| Appendix A NM Method 535 |
| 1. Introduction 537 |
| 2. Technique outline and characteristics 537 |
| 3. Method for Advancing Technique 540 |
| 4. Important Notices 542 |
| 5. Application Field 543 |
| Appendix B The subsequent materials is supplementary material for the finely-tuned use of the DTCN/DTC methodology 551 |
| B-1. Framework Flow Chart For the Storage of Know-how and Cost Management in Enterprises 553 |
| B-2. Creating Mission of Seeds, Needs and Mine or My Own Organization 561 |
| B-3. Creating Customer Needs by Information Node and Concurrent Engineering Flow Chart 563 |
| B-4. What is "Plan to Cost"? 567 |
| B-5. Method for Cost Reduction and Improvements as Manufacturing Sites 581 |
| B-6. Method for effective and proper expediting 593 |
| B-7. Arranging for inquiries and reports, and the status of planning papers and the implementation plan document 601 |
| B-8. Classification and application of the form of meetings 607 |
| Appendix C MIL-STD-499A Engineering Management 609 |
| Appendix D The DTCN/DTC Success Story 635 |
| AppendixーE Design-to-Cost Implementation Standard, Program Plan, Implementation Plan, Formats and Samples of Instructions 651 |
| E-0 Design-to-Cost Implementation Standard 653 |
| E-1 Procedure to Compile Program Plan on Design-to-Cost at Each Planning Level (Unit Production Cost and Development Cost) 681 |
| E-2 Procedure to Compile the Implementation Plan Document for Design-to-Unit-Production-Cost Activity 691 |
| E-3 Procedure to Compile the Implementation Plan Document for Design-to-Development-Cost Activity 707 |
| E-4 Procedure to compile the Verification Procedure Document for Unit Production Cost 723 |
| E-5 Procedure to Compile the Verification Procedure Document for Development Cost 735 |
| E-6 Attached Formats 747 |
| E-7 Examples of Operation Instruction to Implement DTC in Development Design 775 |
| Appendix F One-Page Explanation of DTCN/DTC Methodology 795 |
| 1. The Purpose-Measure Relationship of DTCN Methodology 797 |
| 2. Purpose-Measure Relationship Of Design-To-Cost Using DTCN Methodology 798 |
| 1A. How to Proceed with DTCN (Design-to-Customers'-Needs) 800 |
| 2A. How to Proceed with DTC (Design-To-Cost) 802 |
| Appendix G. A Method for Changing Knowledge to Wisdom and a Wisdom Engine for the Wisdom Management Era 805 |
| Appendix H. A Procedure and Format for the Thinking and Action of "Abduction, Verification, Evaluation and Decision Making" to Reveal Rational Past Mechanisms and to Create Future Mechanisms. By Michihiko Esaki and Kenji Kimura 827 |
| Appendix I. Self-organized flow chart to create and improve goods, products, services, or markets using a multi-screen wisdom desk (combining the QFD, DTCN/DTC, TRIZ and Taguchi Methods) 869 |
| Appendix J. The relationship between QFD, VA/VE and DTCN/DTC methodology by Tatsunori kawai 883 |
| Appendix K. The Method of Project Management/Accounting Using Reversed Journal Position Format 893 |
| The Method to Create a Co-operative Thinking and Working Place Among Science/Engineering and Management/Accounting People- by Tatsunori kawai |
| Appendix L An Autonomic Thinking method for Creative Thinking with the PMD Method by Michihiko Esaki, Shinichiro Kai, Tatsunori Kawai, Yoshikazu Houken 907 |
| Appendix M Training by making a PMD to create a PMD 917 |
