In 2007, the president of a global consumer healthcare products business tasked a team with reducing costs by $250 million. In response to this daunting challenge, the team initiated a number of savings projects. For example, one project cut costs by $3 million by creating multi-language packaging for a dental product. After realizing similar savings on a variety of other projects, team members concluded that they were reaching a savings plateau and would need creative approaches in order to access the next level.
That's when the team's leader turned to a process called idealized design, which had been applied successfully elsewhere in the company. The key feature of idealized design is that participants pretend that the product, process, system, etc. that they are designing was destroyed last night and they are starting from scratch and designing what they ideally want today if they could have whatever they wanted. Doing this frees people up to "think out of the box," unleashing creativity and generating ideas that save money, improve revenues, enhance customer satisfaction, and so on.
The team engaged a facilitator who was experienced with idealized design. He first helped them brainstorm the ideal process for saving money and then helped them cull the best ideas and turn them into implementable designs. For example, they realized that the richest savings opportunities were at the roots of the new product lifecycle rather than in the leaves -- so they designed a program to engage the new product development groups from the very beginning to ensure they bake in an end-to-end lifecycle cost management program and culture. Some of the things they focused on include: global standards (e.g., packaging, active ingredients, flavors, and components); getting product teams to utilize default materials and specifications; and, product formulation harmonization.
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