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3P is a Rapid Event for developing a new product or business product Line. This is an intense few days of cross-functional collaboration which quickly moves through continuous PDCA. This allows rapid learning through the use Try-Storming (brainstorming combined with quick prototyping mock-ups and simulation)
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3P
RAPIDLY
DESIGN A LEAN
MANUFACTURING
PROCESS
(Overview)
It All Starts With a Great Idea for a New Product
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
PRO-ACTIVE SOLUTION
Production Preparation Process
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
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
3P Phases
5. On-Going
Continuous
Improvement
1. Info Gathering
(Pre-Event)
2. Creative
3. Capture
4.Implementation
(Post Event)
Pre-Event
INFORMATION GATHERING
PHASE 1 Customer Requirements 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
_________________________
3-5 Day Event
CREATIVEPHASE
PHASE 2 “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
Try-StormingDevelop 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
3-5 DAY Event
CAPTUREPHASE
PHASE 3 Document the New Process
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
Post Event
IMPLEMENTATIONPHASE
PHASE 4
Turn Concept into reality
Team Meetings Held Weekly or Bi-weekly to Review Status and Communicate Challenges or Modifications
Post Event
CONTINUOUS IMPROVEMENT
PHASE 5 A 3P Event is a great process to begin your journey for
“Operational Excellence”
Team Collaboration
Empowerment
Waste Id. & Elimination
Problem Solving
Challenge Status Quo
Fail Quick and Learn Rapidly
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
OpEx Creative is a lean process design company. We utilize Lean & Six Sigma to help organizations of all sizes and industries to develop, transform, and bring to market new business lines & improve performance of existing lines.
We partner with start-ups to design processes that support new product opportunities.
We provide public & in-house workshops for lean office & services , 3P for services and manufacturing & team problem solving skills.
We help organizations to build the capabilities required to sustain growth.
To schedule a 3P event, training, or just give us a call with any questions.Visit us at: opexcreative.comFree 30 minute Initial Consultation
©2014 OpEx Creative Most Photos from www.pexels.com