3p production preparation process business excellence draft october 5, 2007 be-tl2-010-draft-3p
DESCRIPTION
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.TRANSCRIPT
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3P3P Production Preparation Production Preparation
ProcessProcess Business ExcellenceBusiness Excellence
DRAFTOctober 5, 2007
BE-TL2-010-DRAFT-3P
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2BE-TL2-010-DRAFT-3P
Table of Contents
Overview & Scope 3
Introduction To 3P 5 - 13
11 3P Steps 14 – 24
16 Catchphrases 25 – 24
Process At A Glance 27 - 28
Contents Slide(s)
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3BE-TL2-010-DRAFT-3P
Overview & Scope
OverviewOverview 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.
ScopeScope 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.
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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
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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
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6BE-TL2-010-DRAFT-3P
•Members are the Link for Building In Quality
FixturesMaterials
EquipmentMachinesTools
Material FlowOrganization
Standard WorkInspection SystemsProcess
3P Production Preparation Process
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TOP SECRET
Machines
Build
Using 3P
To Our ProcessesTo Our Products
Applying the Principles
Continuous Improvement
Flextronics Production SystemTM
Simple/Flexible U-Shaped CellsOne-Piece-Flow ErgonomicsTakt Time HanedashiChaku-Chaku Jidoka
Waste Elimination Poka-Yoke
3P Production Preparation Process
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ChangesIn
Demand
ProductDesign
Changes
New Product Introduction
New Plant Introduction
Production Preparation
Process
3P Production Preparation Process
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DEVELOP EFFECTIVE DESIGNS AND PROCESSES
IT’S A COMPETITIVE WEAPON IN OUR INDUSTRY
PROMOTES RAPID CONTINUOUS IMPROVEMENT
3P Production Preparation Process
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Quality
Quantity
Timing
“Builds Appropriate Quality into theProduction Process”
“Highly Flexible and AdaptableProcesses and Equipment”
“New Products or Increased Production
is Delivered ON SCHEDULE ”
3P Production Preparation Process
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1. Machines / Equipment1. Machines / Equipment2. Tooling2. Tooling
3.Layout/Flow3.Layout/Flow
Our Old Way of Thinking AboutCreating a Production Line/Cell
3P Production Preparation Process
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The New Way of
Creating Production Line/Cell
Process/Flow
Producti on P
r epar ati on
Tooling
Machines
3P Production Preparation Process
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Current DesignOr New Design(Preliminary)
Sign YourContracts
BreakdownProduct into
its Parts
DetermineFunction(s)
(1)
What are KEY Words
(2)
FindExamples in
Natural World(3)
Sketch andPost TheseExamples
(4)
SketchBackground
(5)
CombineIdeas-Create
Designs(6)
Post DesignsGroup bySimilarity
(7)
ManufacturingProcess
PreparationProduct Design 3P
ConstructPrototypes
MOONSHINE(8)
Present theDesigns
Select Best 3(9)
KeepMoonshiningGather Data
(10)
Hold TrialSelect Top
Design(11)
Design orRedesign of
Part
3P Production Preparation Process
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1. Determine FunctionWhat is the Theme & Scope of Your Event
FUNCTIONFUNCTION
1. Point 3P2. Line/Cell 3P3. Plant-Wide 3P
Post on Wall/Board
3P Production Preparation Process
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2. Define the Essence of the FunctionWhat are the Key Words
KEY WORDS
Guide
Turn
Drill
Roll
Clamp
Rigidity
Shear
Swivel
Fasten
Spin
Brake
Slide
Oscillate
PressLock
Bond
3P Production Preparation Process
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3. Look for Examples of Keyword in NatureNature has spent millions of years refining these phenomena
Resist All Attempts to Use Man Made ExamplesNature’s Examples are Often Simple and Pure
SpinMove
Encapsulate
Separate
Sting
Grip
Cling
AdhereShear
CrawlBuoyHinge
3P Production Preparation Process
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4. Sketch Examples and Examine What is HappeningGroup Common Examples
Sketch the ExamplesDo Your Homework
Examine in Detail
You MUST Look Deep into the Phenomenon to UnderstandWhat Must Take Place for This Phenomenon to Happen?
Attach Hinge
Group Common Examples
3P Production Preparation Process
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5. Sketch Background and Conditions of FunctionYou 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
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19BE-TL2-010-DRAFT-3P
6. Combine Ideas from Nature---Create SketchesDevelop at least Seven Sketches by each Team Member
Fly
Be Creative. Do NOT Be Afraid To Propose AnythingSeven Proposals
3P Production Preparation Process
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20BE-TL2-010-DRAFT-3P
7. Combine Similar Designs, Pick 7 Methods to BuildPrepare “Process At A Glance” Sheet before Building Proposals
7Designs
Use Readily Available Materials To Build Your PrototypesDo NOT Make This Step Overly Complex
Moonshine
3P Production Preparation Process
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21BE-TL2-010-DRAFT-3P
8. Conduct Experiments and Trials to Collect Real DataHow does each design perform against our criteria?
Collect Real Data Document
The Data
Even Though Your Model is NOT Perfect, It will Give YouValuable Data on How to IMPROVE Your Design
3P Production Preparation Process
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22BE-TL2-010-DRAFT-3P
9. Select 3 Best Designs Base on Criteria, then...Conduct more MOONSHINE on the TOP 3 Designs
Design
Demo/ExplainDesign
Design Evaluation
You MUST Understand the Quality Required.Keep Thinking…”Dimensions, Tolerances, and Gauges.”
3P Production Preparation Process
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23BE-TL2-010-DRAFT-3P
10. Gather and Evaluate Data on Top 3Keep 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
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24BE-TL2-010-DRAFT-3P
11. Bring Together the Functions Select the BEST Design
Proposal #1
Quality
Mfg EngineeringProduct Design
Purchasing
Production
Machine Design
Sales
QA
Tooling Design
Evaluate Committee
Have Models and Data Prepared for Viewing By CommitteeFinalize Design and Start Pre-Production Kaizen Process
3P Production Preparation Process
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3P Production Preparation Process
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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
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163P Production Preparation Process
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28BE-TL2-010-DRAFT-3P
1. Production Preparation should be lightning fast.
3P Production Preparation Process
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29BE-TL2-010-DRAFT-3P
Standard Work
①②③④
2. Equipment Construction and Layout should permit easy material flow.
EnterExit
Material
3P Production Preparation Process
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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
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31BE-TL2-010-DRAFT-3P
Change-over Flowing gap
Old product
New product
5 43
2A
RM
5 43
2B
RM 1
1
5 4C
RM 2 1
53D
RM 2
13E
RM 2
4
13F
RM 2
45
4. Build equipment to allow easy changeovers.
3P Production Preparation Process
Set-ups and changeovers should be made very quickly
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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)
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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
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34BE-TL2-010-DRAFT-3P
7. Make operators stations narrow. Deep is acceptable.
Ranch Style
Layout
Wide and Shallow
TownhouseStyle
Layout
Narrow but Deep
Reduced Walking 1step - station to station
Principle of VerticalityReduced Footprint
3P Production Preparation Process
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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
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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
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37BE-TL2-010-DRAFT-3P
10. Build equipment to fit into small swift vertical flow lines.
MACHINES
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