Potency of the Production Preparation Process (3P)

Clearly Ineffective Google Images of Failed Attempts at Force-feeding This is what failing to follow 3P looks like!

Production Preparation Process (3P) What is 3P??? Production Preparation Process (3P) A component of an overall Lean Design approach Focuses on eliminating waste Shapes how we create products, processes, services, systems of whatever we intend to deliver to a any customer Stems from Toyota Production System – Builds “House of Quality” Represents a dramatic departure from the “old way” of doing things Goes beyond just making something better. We want to design smarter (ETO, not just BTO or Assembly Upon Request) Builds in quality from inception Abandons DANGEROUS market strategy of “Hey, look at this, isn't this cool, can you use it?” Adopts SAFER approach of “Your wish is my command - I listened to you, worked with you, and as a result, this fits you perfectly” (Foundry Mindset)

Production Preparation Process (3P) Getting It Right Production Preparation Process (3P) Define Product or Process Design Objectives/Needs Have cradle to grave representation on team Diagram – Map out your process Specify inputs, outputs, and manipulations (tweakable wheels) Find Process Alternatives Explore all the roads that lead to the same destination Build and Evaluate Prototype Play with toys – a variety of mockups Make sure design criteria met Hold Formal Design Review Subject refined product to critique by expanded population Develop Project Implementation Plan Structure activity for production launch

16 Key Sayings of 3P Getting It Right 1. Production preparation should be lightning fast. Avoid over planning, use what you have, act now. 2. Build & layout equipment for smooth material flow. Flow like a river, not like a dam. 3. Use additive equipment. Buy many speedboats instead of one tanker. 4. Build equipment that is easy to set up. Design in the separation of internal and external tasks. 5. Make equipment easy to move. No roots, no vines, no pits. Put wheels on everything. 6. Use multi-purpose equipment. Simple, “just fast enough” machines that perform one function well. 7. Make operator work stations narrow. Town houses, not ranch houses. 8. Layout equipment for ease of operator movement. Remove obstruction to smooth human motion. 9. Eliminate wasted machine cycle time. Design out ‘air cutting’ and minimize machine movements. 10. Build equipment for small, swift flow lines. Enable Standard Work. 11. Use short, vertical flow lines. Vertical = advancing process flow, horizontal = functional. 12. Build equipment for one-piece pull. Machine level. This is probably the most critical one. 13. Build in quick changeover. Design in SMED at the machine level. 14. Link machines for smooth loading and unloading. Line stops when WIP on the line is “full work”. 15. Use multiple lines & rectified flows. ‘Rectified’ is an odd term, electrical engineers will get it. 16. Spiral upwards to jidoka. Automate with a human intelligence.

3P: The Wise Approach Reasonable Strategy Result: Happy Customer Stop trying to cram food into your customer’s mouth Involve customer in creating something they crave Serve customer something that already has perceived value from their perspective Watch your customer really enjoy what you created together

Hyperlinked References http://www.lean.org http://www.nwlean.net/leandefs.htm http://gembapantarei.com/2006/05/designing_processes_to_fit_lea.html http://gembapantarei.com/2006/05/the_top_5_reasons_for_using_pr.html Toddler's Refusal to Eat Sloppy Joe (Fox News) 4 Hour House Video