LEAN SIGMA SUPPLY CHAIN

Thoughts on Supply Chain, Lean and Six Sigma

D E C E M B E R 7 , 2 0 0 7 B Y L AW R E N C E L O U C K A

Production Preparation Process (3P)

3P Production Preparation Process is an advanced lean approach involving visual

thinking, simulation, kaizen for quick Design For Manufacturability. 3P follows a
series of group and individual activities to sketch and model the product and
processes. Examples in Nature, 7 Ways, Process At A Glance, Moonshine Mock-ups
are all part of the method.

3P is about rapidly designing product and production processes to ensure capability,

built-in quality, productivity, and Flow-Takt-Pull. The Production Preparation Process
minimizes resources needed such as capital, tooling, space, inventory, and time.
Rather than tweaking an existing shop floor process, we start with a clean sheet of
paper. The 3P process is used to develop a product line specific production system in
the shortest time to satisfy design and quality requirements, concept to market time
goals,production requirements, and cost requirements.

3P simulates the actual components, product and production line of a new product
during the early stages of the design process to learn about manufacturing or
delivery requirements before making commitments to a floor plan or process flow.
The goal is to produce a product that meets customer demand with perfect quality
and at the desired cost. From beginning to end, 3P is an exercise in project
management and waste elimination. 3P is a valuable tool because the cost of
eliminating waste in the earliest stages of product development is less than during
the final stages. The tool is useful and effective when you need to develop a method
to meet customer requirements, plan production capacity for new or changing
demand, transition new products, set a target date for delivering to market or prove
the business-case target cost.

The 3P cross-functional team should include designers, engineers (i.e.,

manufacturing, quality and process), operators, operations experts and anyone else
instrumental in bringing the product to market. Using lean principles, the cross-
functional team creates a mock-up of the product and walks through how the
product will flow through the factory. Mock-ups may be made from cardboard, plastic
foam, wood or any other material that makes sense. Multiple 3P events are usually
required throughout the design and development phases of a new product.

Here are the basic steps for 3P:

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DEFINITIONS, LEAN

3 P , L E A N D E S I G N , P R O D U C T I O N P R E PA R AT I O N P R O C E S S

2 Replies to “Production Preparation Process (3P)”

David Cowburn
J A N U A R Y 5 , 2 0 0 9 AT 6 : 2 3 A M

I am preparing a 3P Workshop and would like to use your picture with the guy in a
stripped shirt and team discussing somthing around a mock-up production cell. please
send confirmation to david.cowburn@c4c.ltd.uk.

In return see free resources at http://www.c4c.ltd.uk/downloads.html

Best regards

Lawrence Loucka
J A N U A R Y 5 , 2 0 0 9 AT 9 : 2 8 A M

David, I’m the guy in the striped shirt. Feel free to use the picture, just give attribution –
small footnote referencing resourcesystemsconsulting.com

Comments are closed.