The document describes Production Preparation Process (3P), which is part of a Lean design approach that includes rapid testing of ideas and embedding Lean manufacturing principles into process and product design. 3P uses a cross-functional team to minimize equipment costs, design for one-piece flow, and address issues with new product or process startups. It is suited for complex products/processes with opportunities to cut waste. The 3P Method involves team selection, defining needs, creating prototypes, design reviews, and project planning.

1. Production Preparation Process (3P)Production Preparation Process (3P)
Superfactory Manufacturing Excellence Series
Lean Overview
5S & Visual Factory
Cellular Manufacturing
Jidoka
Kaizen
Poka Yoke & Mistake Proofing
Quick Changeover & SMED
Production Preparation Process (3P)
Pull Manufacturing & Just In Time
Standard Work
Theory of Constraints
Total Productive Maintenance
Training Within Industry (TWI)
Value Streams

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ContentsContents
• Introduction
• Background and History
• Components and Implementation
• Knowledge Check

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IntroductionIntroduction
• Production Preparation Process (3P) is one part of
an overall Lean design approach that includes the
rapid testing of ideas and the embedding of Lean
manufacturing principles into process and product
design.

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Components and ImplementationComponents and Implementation
• What is 3P?
• Why do 3P?
• The 3P Method
– Team Selection
– Define Needs
– Prototypes
– Design Review
– Project Plan

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What is 3P?What is 3P?
• Production Preparation Process (3P) is one part of an
overall Lean design approach that includes QFD,
design reviews, and post-start up monitoring by a
cross functional team to kaizen any bugs in the new
system.
• 3P is one of the most powerful and transformative
advanced manufacturing tools, and it is typically only
used by organizations that have experience
implementing other lean methods.
• Benefits of Production Preparation Process:
– Cross-functional team approach
– Rapid testing of ideas
– The embedding of Lean manufacturing principles into process and
product design.

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Why Do 3P?Why Do 3P?
• 3P to solve one or more difficulties with new
product or process start up. It can be used to
minimize equipment cost or to design processes to
enable one-piece flow. Other opportunities for 3P:
1. New product development. Educate designers in Lean as
early as possible.
2. Capital expenditure approval. Do a 3P review first to ensure
the expenditure is appropriate and necessary.
3. Product design changes. Approve no changes without a 3P
review.
4. Significant changes in volume. Embed Lean into scaled-up
processes.
5. Relocation of processes. A good opportunity to use
3P to embed Lean thinking.

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Why Do 3P?Why Do 3P?
• What types of parts or products are most suited for
3P?
– Anything that has a lot of complexity in it is a good candidate. The
more components, materials, processes, transactions, etc. that are
required to produce and deliver a part, the more opportunity there is
to make drastic improvements through 3P by reconsidering
alternative methods to do it the Lean way.
– The closer you are to "basic science" or a simple process such
as injection molding, the less opportunity you have to consider
new methods. A stamped, machined, painted and welded
assembly on the other hand offers more opportunity to consider
alternative process options and cut out waste. Last but not least,
the best product or process to apply 3P is where there is a high
running cost. Kaizen must make money.

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3P Method: 16 Core Attributes3P Method: 16 Core Attributes
1. Production preparation should be lightning fast.
– Avoid over planning, use what you have, act now.
2. Build & layout equipment for smooth material
flow.
– Flow like a river, not like a dam.
3. Use additive equipment.
– Buy many speedboats instead of one tanker.
4. Build equipment that is easy to set up.
– Design in the separation of internal and external
tasks.