3P Production Preparation Process Business Excellence DRAFT October 5, 2007 BE-TL2-010-DRAFT-3P

2 Table of Contents  Overview & Scope3  Introduction To 3P  11 3P Steps 14 – 24  16 Catchphrases25 – 24  Process At A Glance ContentsSlide(s)

3BE-TL2-010-DRAFT-3P Overview & Scope Overview 3P methods represent a dramatic shift from the continuous, incremental improvement of existing processes sought with kaizen events. Instead, 3P offers potential to make "quantum leap" design improvements that can improve performance and eliminate waste to a level beyond that which can be achieved through the continual improvement of existing processes.Scope The Production Preparation Process (3P) is an approach used to design production processes and equipment to conform to Lean principles such as one-piece flow, building quality into the process, quick changeover, and flexibility. Production Preparation Process involves consideration and testing of various process alternatives, the cross-functional team approach, and providing feedback to product design in order to improve the production process.

4BE-TL2-010-DRAFT-3P Objective  Explain the difference between traditional production preparation and approaches and 3P  Use a Process At A Glance format  Use 7 Ways method for brainstorming  Use life-sized paper cut outs to evaluate layout options

5BE-TL2-010-DRAFT-3P Establishing an Appropriate Production System to Satisfy Requirements of : Product Design Quality Required Production Volume Target Cost Target Date for the at the by the 3P Production Preparation Process

6BE-TL2-010-DRAFT-3P Members are the Link for Building In Quality Fixtures Materials Equipment Machines Tools Material Flow Organization Standard Work Inspection Systems Process 3P Production Preparation Process

7BE-TL2-010-DRAFT-3P TOP SECRET Machines Build Using 3P To Our Processes To Our Products Applying the Principles Continuous Improvement Flextronics Production System TM Simple/FlexibleU-Shaped Cells One-Piece-FlowErgonomics Takt TimeHanedashi Chaku-Chaku Jidoka Waste Elimination Poka-Yoke 3P Production Preparation Process

8BE-TL2-010-DRAFT-3P Changes In Demand Product Design Changes New Product Introduction New Plant Introduction Production Preparation Process 3P Production Preparation Process

9BE-TL2-010-DRAFT-3P DEVELO P EFFECTIVE DESIGNS AND PROCESSES IT’S A COM P ETITIVE WEAPON IN OUR INDUSTRY PROMOTES RA P ID CONTINUOUS IMPROVEMENT 3P Production Preparation Process

10BE-TL2-010-DRAFT-3P Quality Quantity Timing “Builds Appropriate Quality into the Production Process” “Highly Flexible and Adaptable Processes and Equipment” “New Products or Increased Production is Delivered ON SCHEDULE ” 3P Production Preparation Process

11BE-TL2-010-DRAFT-3P 1. Machines / Equipment 2. Tooling 3.Layout/Flow 1. Machines / Equipment 2. Tooling 3.Layout/Flow Our Old Way of Thinking About Creating a Production Line/Cell 3P Production Preparation Process

12BE-TL2-010-DRAFT-3P The New Way of Creating Production Line/Cell Process/Flow Production Preparation Tooling Machines 3P Production Preparation Process

13BE-TL2-010-DRAFT-3P Current Design Or New Design (Preliminary) Sign Your Contracts Breakdown Product into its Parts Determine Function(s) (1) What are KEY Words (2) Find Examples in Natural World (3) Sketch and Post These Examples (4) Sketch Background (5) Combine Ideas-Create Designs (6) Post Designs Group by Similarity (7) Manufacturing Process Preparation Product Design 3P Construct Prototypes MOONSHINE (8) Present the Designs Select Best 3 (9) Keep Moonshining Gather Data (10) Hold Trial Select Top Design (11) Design or Redesign of Part 3P Production Preparation Process

14BE-TL2-010-DRAFT-3P 1. Determine Function What is the Theme & Scope of Your Event FUNCTIONFUNCTION 1. Point 3P 2. Line/Cell 3P 3. Plant-Wide 3P Post on Wall/Board 3P Production Preparation Process

15BE-TL2-010-DRAFT-3P 2. Define the Essence of the Function What are the Key Words KEY WORDS Guide Turn Drill Roll Clamp Rigidity Shear Swivel Fasten Spin Brake Slide Oscillate Press Lock Bond 3P Production Preparation Process

16BE-TL2-010-DRAFT-3P 3. Look for Examples of Keyword in Nature Nature has spent millions of years refining these phenomena Resist All Attempts to Use Man Made Examples Nature’s Examples are Often Simple and Pure Spin Move Encapsulate Separate Sting Grip Cling Adhere Shear Crawl Buoy Hinge 3P Production Preparation Process

17BE-TL2-010-DRAFT-3P 4. Sketch Examples and Examine What is Happening Group Common Examples Sketch the Examples Do Your Homework Examine in Detail You MUST Look Deep into the Phenomenon to Understand What Must Take Place for This Phenomenon to Happen? AttachHinge Group Common Examples 3P Production Preparation Process

18BE-TL2-010-DRAFT-3P 5. Sketch Background and Conditions of Function You must Understand HOW the Natural Phenomenon Operates From This: Remember! You are Using Your 12 Year Old Mindset To This: 105 degrees rotation 48 ～ 94 degrees flex Force uniform Socket Lining 3P Production Preparation Process

19BE-TL2-010-DRAFT-3P 6. Combine Ideas from Nature---Create Sketches Develop at least Seven Sketches by each Team Member Fly Be Creative. Do NOT Be Afraid To Propose Anything Seven Proposals 3P Production Preparation Process

20BE-TL2-010-DRAFT-3P 7. Combine Similar Designs, Pick 7 Methods to Build Prepare “Process At A Glance” Sheet before Building Proposals 7 7 Designs Use Readily Available Materials To Build Your Prototypes Do NOT Make This Step Overly Complex Moonshine 3P Production Preparation Process

21BE-TL2-010-DRAFT-3P 8. Conduct Experiments and Trials to Collect Real Data How does each design perform against our criteria? Collect Real Data Document The Data Even Though Your Model is NOT Perfect, It will Give You Valuable Data on How to IMPROVE Your Design 3P Production Preparation Process

22BE-TL2-010-DRAFT-3P 9. Select 3 Best Designs Base on Criteria, then... Conduct more MOONSHINE on the TOP 3 Designs Design Demo/Explain Design Evaluation You MUST Understand the Quality Required. Keep Thinking…”Dimensions, Tolerances, and Gauges.” 3P Production Preparation Process

23BE-TL2-010-DRAFT-3P 10. Gather and Evaluate Data on Top 3 Keep MOONSHINING and Improve On Design. If Problems Arise... Fix Them Right on the Spot, Don’t Talk About Them Keep TRY-storming…Not Brainstorming 3P Production Preparation Process

24BE-TL2-010-DRAFT-3P 11. Bring Together the Functions Select the BEST Design Proposal #1 Quality Mfg Engineering Product Design Purchasing Production Machine Design Sales QA Tooling Design Evaluate Committee Have Models and Data Prepared for Viewing By Committee Finalize Design and Start Pre-Production Kaizen Process 3P Production Preparation Process

25BE-TL2-010-DRAFT-3P 3P Production Preparation Process

26BE-TL2-010-DRAFT-3P 1. Flow production engineering 2. Machine engineering 3. Plasticity (molding, forging, rolling, etc) Engineering 4. Die engineering, Tooling 3P Production Preparation Process

27BE-TL2-010-DRAFT-3P 16 3P Production Preparation Process

28BE-TL2-010-DRAFT-3P 1. Production Preparation should be lightning fast. 3P Production Preparation Process

29BE-TL2-010-DRAFT-3P Standard Work ① ② ③ ④ 2. Equipment Construction and Layout should permit easy material flow. Enter Exit Material 3P Production Preparation Process

30BE-TL2-010-DRAFT-3P 3. Build additive equipment. No battleships. 3P Production Preparation Process Begin by purchasing machines with the bare minimum of functions and then add them as they become necessary

31BE-TL2-010-DRAFT-3P Change-over Flowing gap Old product New product A RM B C D E F Build equipment to allow easy changeovers. 3P Production Preparation Process Set-ups and changeovers should be made very quickly

32BE-TL2-010-DRAFT-3P Machine 5. Make equipment easy to disconnect and relocate. Machine 3P Production Preparation Process Install wheels or casters to the machines to allow quick response to line changes Avoid attaching vines (wiring, ductwork, piping, or other items from other lines). Avoid attaching permanent roots to floor (cabling, piping, wiring, or supporters)

33BE-TL2-010-DRAFT-3P Big Dedicated Machines 6. Use Versatile Equipment Fully dedicated machines must be discarded when new products replace old. Equipment that is basically multipurpose can be used for new products. 3P Production Preparation Process

34BE-TL2-010-DRAFT-3P 7. Make operators stations narrow. Deep is acceptable. Ranch Style Layout Wide and Shallow Townhouse Style Layout Narrow but Deep Reduced Walking 1step - station to station Principle of Verticality Reduced Footprint 3P Production Preparation Process

35BE-TL2-010-DRAFT-3P 8. Both the equipment and layout should allow the operator to move easily. Open room concept allows operators to see the big picture. Fixed Layout Standard work may be changed to for increased demand without changing layout. 3P Production Preparation Process

36BE-TL2-010-DRAFT-3P 1.Switch on 2.Air cutting down (Muda) 3.Drilling 4.Air cutting up (Muda) Only this part adds VALUE MUDA 9. Eliminate machine waste. Kaizen the motion of the machine. Air cutting 3P Production Preparation Process Eliminate air cutting by moving the cutter closer to the work piece

37BE-TL2-010-DRAFT-3P 10. Build equipment to fit into small swift vertical flow lines. MACHINES 3P Production Preparation Process

38BE-TL2-010-DRAFT-3P Vertical Flow Press Weld Paint Assy. Press Weld Paint Assy. Press Weld Paint Assy. Press Weld Paint Assy. Horizontal Handling NO FLOW Products A BCD Process 11. Eliminate horizontal flow. This creates a batch processing. 3P Production Preparation Process

39BE-TL2-010-DRAFT-3P 12. Production should be pulled along at Takt time. Do not allow room or capability for batching. One per Day Don’t Produce 7 units once per week when the customer wants 1 per day. 1 Day 1 Day Takt Time = 1 Day 3P Production Preparation Process

40BE-TL2-010-DRAFT-3P 13. Build tooling/machines for rapid setups and quick changes. Ease of positioning 3P Production Preparation Process

41BE-TL2-010-DRAFT-3P 14. Link machines to make work flow smoothly and avoid excessive WIP. Whoa! NO MORE WIP 1 piece is Standard 1 3P Production Preparation Process

42BE-TL2-010-DRAFT-3P 15. Use multiple lines to avoid constructed flow. B1 B2 B3 B4 F1 F2 F3 F4 P1 P2 P3 P4 A1 A2 A3 A4 Model A Model B Model C Model D B1 B2 F1 F2 F3 F4 P1 A1 A2 A3 Model A Model B Model C Model D B = Blank F = Fabricate P = Paint A = Assembly Use Multiple and Rectified Flows 3P Production Preparation Process

43BE-TL2-010-DRAFT-3P 16. Continue pursuing the steps of Jidoka by spiraling upwards continuously separating machine tasks from human tasks. 7 Quality Check (Poka-Yoke) Part Removal (Hanedashi) Automation of Returns Automation of Stops Automation of Feed Automation of Holding Autonomation of processing Jidoka 3P Production Preparation Process

44BE-TL2-010-DRAFT-3P 3P Chart Process At A Glance

45BE-TL2-010-DRAFT-3P 3P Chart Process At A Glance