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)

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.

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

FixturesMaterials

EquipmentMachinesTools

Material FlowOrganization

Standard WorkInspection SystemsProcess

3P Production Preparation Process

7BE-TL2-010-DRAFT-3P

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

8BE-TL2-010-DRAFT-3P

ChangesIn

Demand

ProductDesign

Changes

New Product Introduction

New Plant Introduction

Production Preparation

Process

3P Production Preparation Process

9BE-TL2-010-DRAFT-3P

DEVELOP EFFECTIVE DESIGNS AND PROCESSES

IT’S A COMPETITIVE WEAPON IN OUR INDUSTRY

PROMOTES RAPID CONTINUOUS IMPROVEMENT

3P Production Preparation Process

10BE-TL2-010-DRAFT-3P

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

11BE-TL2-010-DRAFT-3P

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

12BE-TL2-010-DRAFT-3P

The New Way of

Creating Production Line/Cell

Process/Flow

Producti on P

r epar ati on

Tooling

Machines

3P Production Preparation Process

13BE-TL2-010-DRAFT-3P

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

14BE-TL2-010-DRAFT-3P

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

15BE-TL2-010-DRAFT-3P

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

16BE-TL2-010-DRAFT-3P

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

17BE-TL2-010-DRAFT-3P

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

18BE-TL2-010-DRAFT-3P

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

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

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

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

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

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

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

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

163P 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

①②③④

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

EnterExit

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

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

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

TownhouseStyle

Layout

Narrow but Deep

Reduced Walking 1step - station to station

Principle of VerticalityReduced 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

38BE-TL2-010-DRAFT-3P

39BE-TL2-010-DRAFT-3P

40BE-TL2-010-DRAFT-3P

41BE-TL2-010-DRAFT-3P

42BE-TL2-010-DRAFT-3P

43BE-TL2-010-DRAFT-3P

44BE-TL2-010-DRAFT-3P

45BE-TL2-010-DRAFT-3P