3P Event - Lessons & Learns

Lessons and Learns in the 3P Kaizen
By Yongshan Chen, Naijiang Xu & Frank Qu
9-15-2012, Piqua, Ohio
Yongshan Chen (Engineering Manager, Crane Zhuji):
1.3P (Production Preparation Process) is a unique tool quite different from the traditional NPD. After collected the
voice of customers (VOC), the engineering department (or the sales dept.) needs to summarize a general plan for the new product to be developed, such as the 32 Frame pump development by this 3P event. The requirements and the standard for this new product can thus be understood by all departments.
2.The purpose of 3P is to allow the sales, the production, the test and the service persons to be involved in the NPD
process early, and thus to minimize the time required for the NPD. This method maximizes the use of the existing production equipment, the test equipment and the resources in the worksite and thus can significantly reduce the cost for the NPD.
3.The detail procedure of 3P is to get a Kaizen team working five days. Several sub teams will work out seven
different designs for the new product based on the company strategy. Then the team will utilize the tools such as fish bone to define the function components. Then the team will use the Pugh Matrix and filled out the scores for the three narrowed designs, generate moonshines and eventually optimize the final design which will meet the required functions to the best.
The final design will need to make a true size model. Then the team will work out the assembly process, the fixtures required and finish the cost analysis. The new product report is then generated.
4.The 3P Kaizen needs the support and attention from the company’s leaders from all functional departments. The
Kaizen team needs to arrange meetings and report the Kaizen event progress everyday. It is important that the Kaizen progress must be audited and accepted by these leaders.
5.If Crane Zhuji uses 3P in NPD, pre-work should be done by the engineering department prior the Kaizen starts.
The basic work includes 3-5 basic designs for discussion in the event. The Kaizen team can review these designs together and sort out the best one from them. From this point the moonshines may be created, the assembly process can be developed and the cost for tooling, equipment and the pump can be generated. A final report can thus be created. This procedure may be more suitable to Crane Zhuji.
6.Finally, I will thank Jim Lavish and Jason Fletcher for giving us the opportunity to participate this Kaizen, thanks
for Frank Qu’s help in translation, than ks for the hotel and transportation supplied by CP&S. I also thank Mark Kowalak, Brandon Cross and other team members who gave us detail explanation during the event.
Naijiang Xu (Chief Design Engineer, Crane Zhuji):
1.I feel very lucky to have this opportunity to participate the 3P Kaizen in CP&S. During this Kaizen event I saw a
lot of work cells which gave me deep impression. I truly believe that these advanced cells are the guarantee to produce high quality products.
2.Every department of CP&S uses high advantage management tools and methods. I believe that these tools and
methods further guarantee that high quality products can be produced. Examples are the large machining center in 3rd street facility and the fixtures in the shop. All tools and fixtures are put in order in the shop. Safety signs are clearly marked in the shop. The KPI boards in the cells are the guarantee for high quality and safety.
3.3P event is a new concept to us. However, through the one week participation and study in CP&S, I think the 3P
event supplied the scientific tools and foundation for new product plan, design, test and production. I learnt a lot through this weekly long study.
4.With the deep impression of 3P Kaizen event, I will spend more time to further study the 3P Kaizen method after
returning to Zhuji, and use the 3P method and its concept in Zhuji domestic pump development.
5.Here I thank Jim Lavish and Jason Fletcher for giving this training opportunity in Piqua. At the same time I thank
Mark Kowalak and Frank Qu for their help during this 3P event. I specially thank CP&S for supplying hotel room and taxi support. I hope I will have more opportunity to study in CP&S in the future. I also hope CP&S leaders will visit Zhuji facility often and give instructions and suggestions in production and NPD.
Frank Qu (Project engineer, CP&S):
This 3P event is a new tool to me. Many new concepts were introduced in this event. We have learnt a lot through this event, such as the NPD procedure with the voices from all functional departments.
During this week long study, we learnt how to use the 7 flows to bridge the gap between the engineering and manufacturing. We learnt the concept of creating 7 designs within the team and narrowing them down to 3 best designs, the scoring methods and the factors while evaluating a design, and the fishbone analysis to realize function goals. These concepts are big help to new pump development in Crane Zhuji.
The methods of using nature features in function design are interesting. The concepts are new to me. But I did not find those features were used in the pump. May be I missed.
The team work showed its power in NPD. Three true size models were quickly made for analysis and the final and the best design was decided in one week. Most important of all, the final design was accepted by all functional departments of the company. As discussed in the Kaizen, this is the first step and the most important for a successful new product design.
After the Kaizen I thought about the 7 designs on the second day of the Kaizen. At that time I felt difficult to create the new design for the pump in the sky. I felt difficult to create a design in 45 minutes. This short time only allowed me to think about an improvement design in part of the pump. Later on when we built model pumps, the scale of the pump model bothered me. Although the model we built (with Mr. Chen and Mr. Xu) was selected as the basic for the final model, I am concerning whether its non-scale portion will mislead the readers. I hope it won’t. I heard Piqua engineering would do more work on the design.
Anyway I think it is better to do some more preparation work prior the 3P event, such as to create a few CAD drawings in scale and put them on the wall during the Kaizen. These drawings can be done with following information:
1)V oice of customer (should be done prior the event)
2)Previous design of similar pump (such as 18 or 28 Frame size)
3)Basic motor size for the new pump
4)Components made before (seal plates, bearing seat etc.)
With the drawings on the wall, the participants (especially those not from engineering department and those from out of CP&S) can better understand where to start with. The scale drawings can also help make the new pump models more realistic.
In general, this Kaizen gave me brand new method in NPD. So I like to participate more 3P Kaizen events in the future. Scale drawing is my favorite and I like to work on this.
Finally, I want to thank Jim Lavish and Jason Fletcher for giving me this chance to participate the Kaizen, and the team members who answered my questions with patience.
END。