This document discusses production preparation process (3P), a cross-functional team approach for designing lean production processes for new or modified production lines. The 3P methodology involves bringing together members from planning, production, quality, logistics, engineering, and suppliers to understand the designed production process using prototypes and mock-ups. This helps test assumptions before equipment is ordered and installed. Key benefits of 3P workshops include a smooth start of production without major issues, avoiding surprises after production starts, and early alignment of stakeholders.
6. What is Production Preparation Process ?
A Cross Functional Team comprising
members from Planning,
Production, Quality, Logistics,
Engineering and Suppliers
understand and evaluate the designed
production process and define
alternatives. Using prototypes or
simple materials, mock up the process
to test the premises and assumptions
before the actual equipment is ordered
and installed.
A proactive and well-organized methodology for designing a LEAN
production process for green -field or brown-field projects
Implementation of this approach
is called as 3P-WORKSHOP
7. Real Place, Real Parts,
Real Data
Because, reality is
different from theory.
Touch the part and feel
the process would give
much better solutions
All the key stake holders, like
Planner, production manager,
Quality manager, Logistics
Manager- come out from their
silo and align their thought
process and their plans
It defines the basic
standardized work.
Line starts with
standardized work. It
enables the CI
process.
Production Preparation Process WS
Early alignment of key stakeholders at Gemba with mock-up process, leads to
standard process before SoP and sets the foundation for Continuous Improvement
What is Production Preparation Process ?
8. When to use 3P ?
• New product introduction
• New production line implementation
• Capacity increase / decrease from existing
production line
• New Technology / Equipment Implementation
• Relocate / shifting of Lines
• Re-engineering an existing production line
9. 1. Process Planning
2. Production
3. Quality
4. Logistics
5. Engineering
6. LEAN/ Opex (facilitator)
7. Supplier
8. Process Experts
3P team normally comprise of members from all
key functions
11. 1. LEAN assessment report
2. Work Station layout
3. Manpower allocation /
Utilization%
4. Work station utilization %
5. Refined Process Planning
6. Tools / equipment design
7. Logistics data / storage bin
details / Kart details
8. Ergonomics Risk
Landscape
9. Standard Job/Work
Instruction Sheets
10. Manufacturability – Open
issues
Planning
3PWorkshops
Process Plan, Tool/ Jigs /Fixture
design, station layout, material
conveying design
Production
Experience, physical resources,
shop floor facility, mock-up
material
Quality
Quality requirements, inspection
plan, check lists, inspection tools,
key characteristics
Logistics
Master list of parts, supply
details, kart designs, line side
storage design,
Engineering
Product design, assembly
drawings, specifications, key
characteristics
Input Output
3P workshop typical outcome
12. Ergonomics
Line Side
parts Storage
O.H material
handling
facilities
Assembly
Process /
Sequence
Station
Layout
LEAN
requirements
(7 Wastes)
Quality
requirements
3P helps in synchronization of all these features of a
production line, leading to a smooth start of production (SoP)
13. Major Benefits of the 3P workshops
3P leads to very smooth start of line without any major teething problems.
It avoids rather “Surprises which arise after the line starts
running”(e.g. shifting of some OH facility, rebalancing of the line,
correcting the layout)
The cost, efforts and time necessary for overcoming such surprises are
always higher than the cost of 3P workshops
Alignment of all key stakeholders who are getting an opportunity to
preconceive the process and align themselves effectively
Design issues related to Manufacturability are addressed well before
start of production
