By Jon Miller | Post Date: October 25, 2006 10:18 PM | Comments: 13
Apoorva from India asks, "Generally how many alternatives are worked out in 3P?" Production Preparation Process, or 3P as it is known, is the name used to describe the American consulting market's understanding of the Shingijutsu consulting company's understanding of the Toyota Motor Corporation's approach to process development and production preparation. In a previous post we discussed the 16 catch phrases of 3P which are an embedded thought process for this type of production preparation.
When you are designing equipment, or a production line that is built from a series of processes and connected equipment, you need to identify alternatives for each step. This can be tedious. Most engineers who are first faced with 3P balk at this exercise when there is a catalog full of solutions. Generating seven alternatives can be like pulling teeth. Plenty of "stupid ideas" are needed. A cross functional team is definitely recommended.
After creating a charter for a 3P project to define the scope and desired outcome, a properly trained production preparation team would use the Process At A Glance to develop seven alternatives, evaluate the seven alternatives to select top three, sketch out model operations on Process At A Glance, simulate the three alternatives as and then select top process design.
The simulation can involve building 3D (three dimensional) mock ups using cardboard, wood, duct tape, etc. to get as close to the concept as possible, quickly. Once the size, shape and functions performed are defined actual functioning models can be built and tested. The more simulation you can do, the closer your models will be to the final item.
The main reasons to start "inside out" from value added transformation or feature creation ("make hole") to the fixture, the controls, the box instead of "outside in" by selecting a machine out of a catalog is that it helps avoid buying or building machines with lots of unnecessary accessories.
The idea of 3P is to build bare bones machine with human wisdom and designed for quick changeovers, pokayoke and one piece flow. This requires thinking through several alternatives and then asking the questions which direct your thinking towards kaizen. The following guidelines can be used for evaluating and ranking the alternatives:
Q-1 Pokayoke is built into the process
That's how to use 3P to work out process design alternatives. Thanks for the question.Comments are moderated to filter spam and inappropriate content. There may be a delay before your comment is published.