The document describes a 3P (Production Preparation Process) event, which is an intense 3-5 day workshop to design lean manufacturing processes. A cross-functional team collaborates in the 3P to develop waste-free systems focused on material and information flow. Through rapid prototyping and testing alternatives, the team aims to launch new products and processes quicker with reduced costs and built-in quality. The 3P follows phases of information gathering, creative development of alternatives, capturing the new process design, implementation, and ongoing continuous improvement.

1. 3P
RAPIDLY
DESIGN A LEAN
MANUFACTURING
PROCESS
(Overview)

2. It All Starts With a Great Idea for a
New Product

3. 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

4. PRO-ACTIVE SOLUTION
Production Preparation Process

5. 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

6. 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

7. 3P
Phases
5. On-Going
Continuous
Improvement
1. Info Gathering
(Pre-Event)
2. Creative
3. Capture
4.Implementation
(Post Event)

8. PHASE 1  Customer Requirements
INFORMATION
GATHERING
Pre-Event
 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
 _________________________

9. PHASE 2
CREATIVE
PHASE
3-5 Day Event
 “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

10. Try-Storming
Develop 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

11. PHASE 3 Document the New Process
CAPTURE
PHASE
3-5 DAY Event
 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

12. PHASE 4
IMPLEMENTATION
PHASE
Post Event
 Turn Concept into reality
 Team Meetings Held
Weekly or Bi-weekly to
Review Status and
Communicate Challenges
or Modifications

13. PHASE 5 A 3P Event is a great process to
CONTINUOUS
IMPROVEMENT
Post Event
begin your journey for
“Operational Excellence”
 Team Collaboration
 Empowerment
 Waste Id. & Elimination
 Problem Solving
 Challenge Status Quo
 Fail Quick and Learn Rapidly

14. 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

15. 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.com
Free 30 minute Initial Consultation
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