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

3P3P Production Preparation Production Preparation

ProcessProcess Business ExcellenceBusiness Excellence

DRAFTOctober 5, 2007

BE-TL2-010-DRAFT-3P

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)


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.


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


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


•Members are the Link for Building In Quality

FixturesMaterials

EquipmentMachinesTools

Material FlowOrganization

Standard WorkInspection SystemsProcess



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



ChangesIn

Demand

ProductDesign

Changes

New Product Introduction

New Plant Introduction

Production Preparation

Process



DEVELOP EFFECTIVE DESIGNS AND PROCESSES

IT’S A COMPETITIVE WEAPON IN OUR INDUSTRY

PROMOTES RAPID CONTINUOUS IMPROVEMENT



Quality

Quantity

Timing

“Builds Appropriate Quality into theProduction Process”

“Highly Flexible and AdaptableProcesses and Equipment”

“New Products or Increased Production

is Delivered ON SCHEDULE ”



1. Machines / Equipment1. Machines / Equipment2. Tooling2. Tooling

3.Layout/Flow3.Layout/Flow

Our Old Way of Thinking AboutCreating a Production Line/Cell



The New Way of

Creating Production Line/Cell

Process/Flow

Producti on P

r epar ati on

Tooling

Machines



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



1. Determine FunctionWhat is the Theme & Scope of Your Event

FUNCTIONFUNCTION

1. Point 3P2. Line/Cell 3P3. Plant-Wide 3P

Post on Wall/Board



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



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



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



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



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



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



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



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.”



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



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



1. Flow production engineering

2. Machine engineering

3. Plasticity (molding, forging, rolling, etc) Engineering

4. Die engineering, Tooling



1. Production Preparation should be lightning fast.



Standard Work

①②③④

2. Equipment Construction and Layout should permit easy material flow.

EnterExit

Material



3. Build additive equipment. No battleships.


Begin by purchasing machines with the bare minimum of functions and then add them as they become necessary


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.


Set-ups and changeovers should be made very quickly


Machine

5. Make equipment easy to disconnect and relocate.

Machine


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)


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.



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



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.



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


Eliminate air cutting by moving the cutter closer to the work piece


10. Build equipment to fit into small swift vertical flow lines.

MACHINES

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

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