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

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