3P_Training

Combine Ideas-Create Designs (6) Present the Designs Select Best 3 (9)
Sketch Background (5)
Sketch and Post These Examples (4) Hold Trial Select Top Design (11)
Production Preparation Process
Building Quality into Our Production System
5. Sketch Background and Conditions of Function
You must Understand HOW the Natural Phenomenon Operates
All of these must be evaluated
Production Preparation Process
Building Quality into Our Production System
Current Design Or New Design
Sign Your Contracts
Post on Wall/Board Resist the Urge to Examine the Existing Process. This will only Create a Bias and Stifle Creativity.
Production Preparation Process
Production Flow
Process
Members
are the Link for Building In Quality
The 3P process requires us to use
Rapid Continuous Improvement
Applying the Principles
Building Quality into Our Production System
1. Determine Function
FUNCTION
What is the Theme & Scope of Your Event
1. Point 3P 2. Line/Cell 3P 3. Plant-Wide 3P
Building Quality into the Process
PROCESS
3P
3P Doer’s Training Manual
1
Production Preparation Process
What Is 3 P ?
•Product Design Quality •Required Production Volume •Target Cost •Target Date
Production Preparation Process
Building Quality into Our Production System
8. Conduct Experiments and Trials to Collect Real Data
How does each design perform against our criteria?
Collect Real Data
Document
The Data
Even Though Your Model is NOT Perfect, It will Give You Valuable Data on How to IMPROVE Your Design.
Production Preparation Process
Production Preparation Process
Building Quality into Our Production System
Quality Quantity
“Builds Appropriate Quality into the Production Process” “Highly Flexible and Adaptable Processes and Equipment” “Focus on Reducing Both Capital Costs and Product Costs” “New Products or Increased Production is Delivered ON SCHEDULE ”
(Preliminary)
Breakdown Product into its Parts
Determine Function(s) (1)
What are KEY Words (2)
Post Designs Group by Similarity (7) Construct Prototypes MOONSHINE (8)
Find Examples in Natural World (3) Design or Redesign of Part
Keep Moonshining Gather Data (10)
Product Design 3P
Manufacturing Process Prep.
Production Preparation Process
IT’S A COMPETITIVE WEAPON IN OUR INDUSTRY PROMOTES RAPID CONTINUOUS IMPROVEMENT
When is 3P used
•New Plant Introductions •Changes In Demand •Product Design Changes •New Product Introductions
Simple/Flexible
U-Shaped Cells
One-Piece-Flow
Ergonomics
Takt Time Hanedashi Jidoka Chaku-Chaku Waste Elimination Poka-Yoke
Why do 3P
DEVELOP EFFECTIVE DESIGNS AND PROCESSES
Production Preparation Process
Building Quality into Our Production System
Fixtures Materials Equipment Machines Tools
Material Flow Just In Time Standard Work
Building Quality into Our Production System
9. Select the Three Best Designs Base on Criteria, then...
Conduct more MOONSHINE on the TOP 3 Designs.
Design
From This:
To This:
105 degrees rotation
Socket Lining
Force uniform
48～94 degrees flex
Remember! You are Using Your 12 Year Old Mindset.
Production Preparation Process
Fly
Seven Proposals
Be Creative. Do NOT Be Afraid Propose Anything!
Production Preparation Process
7. Combine Similar Designs. Pick 7 Methods to Build
Prepare “Process At A Glance” Sheet before Building Proposals.
Cost Timing
Production Preparation Process
Building Quality into Our Production System
1. Machines / Equipment
2. Tooling yout/Flow
Our Old Way of Thinking About Creating a Production Line/Cell
Oscillate
Press
Turn
Roll Drill Shear
Production Preparation Process
Building Quality into Our Production System
3. Look for Examples of Keyword in Nature
Nature has spent millions of years refining these phenomena.
Building Quality into Our Production System
7
Designs
Moonshine
Use Readily Available Materials To Build Your Prototypes. Do NOT Make This Step Overly Complex.
Building Quality into Our Production System
6. Combine Ideas from Nature---Create Design Sketches
Develop at least Seven Design Sketches by each Team Member
Building Quality into Our Production System
2. Define the Essence of the Function