The document describes a 3P (Production Preparation Process) event, which is an intense 3-5 day workshop to design lean manufacturing processes. A cross-functional team collaborates in the 3P to develop waste-free systems focused on material and information flow. Through rapid prototyping and testing alternatives, the team aims to launch new products and processes quicker with reduced costs and built-in quality. The 3P follows phases of information gathering, creative development of alternatives, capturing the new process design, implementation, and ongoing continuous improvement.
3. However After Launch……
• Capital Investments &
Operating Costs - Over Budget
• Poor Customer Service & Long
Lead-Times
• Batch Processing - No Flow
• Rework Loops Everywhere
• Environmental, Ergonomic &
Safety Issues
• “Thrown Over Wall”: All key
Members Upset They Were
Not Involved in Process Design
5. WHAT IS 3P?
Intense 3-5 Day Event
A Focus on Developing a Waste-Free System
Concentrating on Flow of Material & Information
Cross-Functional Collaboration (Engineering,
Operations, Facilities, Planning, Finance….)
Try-storming using Rapid Prototyping & Testing
Numerous Alternatives are Developed for Each
Process Step and Overall System.
Team is encouraged to Fail Quick & Often
Through Continuous PDCA for Rapid Learning
Great way to begin the Journey of Operational
Excellence
6. WHEN TO USE 3P
New Product or a New Business Line
Design Changes in an Existing Product
Changes In Demand: Increase or Decrease
New Technology or Equipment
Relocation of Process (Internally or Externally)
Current Process Just Needs a Complete Overhaul
Should be performed concurrently with the
Product Design Process
8. PHASE 1 Customer Requirements
INFORMATION
GATHERING
Pre-Event
Projected Volumes & Ramp Up
Schedule
Variations of Product/Part #’s
Product Drawings & Details
Samples: Raw, Components &
Finished Product
Environmental, Health, &
Safety Considerations
Initial Process Map
Information on Any Pre-
Selected Equipment or Shared
Resources
_________________________
9. PHASE 2
CREATIVE
PHASE
3-5 Day Event
“Designing a Lean Process”
Training (Can be provided before the event)
Development of Selection
Criteria
Teams Divided into Small
Groups
Min. of 7 Alternatives Designed
thru Try-Storming for Each Step
Identify Error Proofing
Solutions: “Build Quality In”
Ideas Developed and Tested
Quickly (Fail Quick and Learn
Rapidly)
Create a Full Scale Mock-Up of
Overall System
10. Try-Storming
Develop Prototypes of Workstations, Equipment, fixtures, Conveyance,
etc…Quickly so they can be tested.
They do not have to be exact – Just good enough so you can quickly see
the concept. (Remember to identify any Mistake-Proofing
Opportunities/Solutions.)
Teams explore thru hands-on creativity. Prototype Mock-Ups can be
Small Scaled or Large Actual-Size. Sketches can also be made on Large
Post Cards or Flip Chart Paper.
Potential Materials
PVC Piping
3D Paper models
Cardboard
Building Blocks
Wood
Popsicle Sticks
Items From Your Garage
Flip Chart Paper
Different Colored Paper
Plenty of Packing tape or duct tape
11. PHASE 3 Document the New Process
CAPTURE
PHASE
3-5 DAY Event
New Process Flow/ VSM
Takt-Time/Cycle Time
Process Capacity
Standard Work Sheets
Pictures and Video
Layout
Implementation Plan (Present results
of event & plan with all team members that were unable
to attend Event)
Follow-Up Meeting Schedule
12. PHASE 4
IMPLEMENTATION
PHASE
Post Event
Turn Concept into reality
Team Meetings Held
Weekly or Bi-weekly to
Review Status and
Communicate Challenges
or Modifications
13. PHASE 5 A 3P Event is a great process to
CONTINUOUS
IMPROVEMENT
Post Event
begin your journey for
“Operational Excellence”
Team Collaboration
Empowerment
Waste Id. & Elimination
Problem Solving
Challenge Status Quo
Fail Quick and Learn Rapidly
14. WHAT ARE THE
BENEFITS OF 3P?
Launch Time Quicker, Reduced Cost, Built in Quality
& Higher ROI
Customer Focused Process
Gives Team a Deeper Hands-On Understanding
Lean Methodology and Operational Excellence
Cross-Functional Collaboration
Teaches Team about Rapid Learning through
Continuous PDCA
Gives a Connection & Deep Understanding of the
New Manufacturing Process for All Team Members