Production Preparation Process (3P) Superfactory Manufacturing Excellence Series Lean Overview 5S & Visual Factory Cellular Manufacturing Jidoka Kaizen Poka Yoke & Mistake Proofing Quick Changeover & SMED Production Preparation Process (3P) Pull Manufacturing & Just In Time Standard Work Theory of Constraints Total Productive Maintenance Training Within Industry (TWI) Value Streams

© 2007 Superfactory™. All Rights Reserved. Contents Introduction Background and History Components and Implementation Knowledge Check © 2007 Superfactory™. All Rights Reserved.

© 2007 Superfactory™. All Rights Reserved. Introduction Production Preparation Process (3P) is one part of an overall Lean design approach that includes the rapid testing of ideas and the embedding of Lean manufacturing principles into process and product design. © 2007 Superfactory™. All Rights Reserved.

Components and Implementation What is 3P? Why do 3P? The 3P Method Team Selection Define Needs Prototypes Design Review Project Plan © 2007 Superfactory™. All Rights Reserved.

© 2007 Superfactory™. All Rights Reserved. What is 3P? Production Preparation Process (3P) is one part of an overall Lean design approach that includes QFD, design reviews, and post-start up monitoring by a cross functional team to kaizen any bugs in the new system. Benefits of Production Preparation Process: Cross-functional team approach Rapid testing of ideas The embedding of Lean manufacturing principles into process and product design. 3P is one of the most powerful and transformative advanced manufacturing tools, and it is typically only used by organizations that have experience implementing other lean methods. © 2007 Superfactory™. All Rights Reserved.

© 2007 Superfactory™. All Rights Reserved. Why Do 3P? 3P to solve one or more difficulties with new product or process start up. It can be used to minimize equipment cost or to design processes to enable one-piece flow. Other opportunities for 3P: New product development. Educate designers in Lean as early as possible. Capital expenditure approval. Do a 3P review first to ensure the expenditure is appropriate and necessary. Product design changes. Approve no changes without a 3P review. Significant changes in volume. Embed Lean into scaled-up processes. Relocation of processes. A good opportunity to use 3P to embed Lean thinking. © 2007 Superfactory™. All Rights Reserved.

© 2007 Superfactory™. All Rights Reserved. Why Do 3P? What types of parts or products are most suited for 3P? Anything that has a lot of complexity in it is a good candidate. The more components, materials, processes, transactions, etc. that are required to produce and deliver a part, the more opportunity there is to make drastic improvements through 3P by reconsidering alternative methods to do it the Lean way. The closer you are to "basic science" or a simple process such as injection molding, the less opportunity you have to consider new methods. A stamped, machined, painted and welded assembly on the other hand offers more opportunity to consider alternative process options and cut out waste. Last but not least, the best product or process to apply 3P is where there is a high running cost. Kaizen must make money. © 2007 Superfactory™. All Rights Reserved.

3P Method: 16 Core Attributes Production preparation should be lightning fast. Avoid over planning, use what you have, act now. Build & layout equipment for smooth material flow. Flow like a river, not like a dam. Use additive equipment. Buy many speedboats instead of one tanker. Build equipment that is easy to set up. Design in the separation of internal and external tasks. © 2007 Superfactory™. All Rights Reserved.