By Jon Miller | Post Date: January 4, 2010 10:10 PM | Comments: 1
Production Preparation Process was coined and formalized by Mr. Chihiro Nakao, founder of the Shingijutsu Consulting company and possibly the world's greatest production engineer. He would like to be remembered as the Father of Moonshine. The Father of Moonshine is pictured above wearing glasses, between Ms. Corvi and Mr. Hersher. The photo is from the April 2006 Boeing Frontiers journal in which the lean practice of moonshine is explained:
Attending the 2006 Boeing Commercial Airplanes Moonshine Wars event are (from left) Carolyn Corvi, Airplane Production vice president and general manager; Chihiro Nakao, the former Shingijutsu Consulting president who's considered the "father of Moonshine"; and Commercial Airplanes Lean Enterprise Office Director Mike Herscher. They're looking at one team's Moonshine ideas, which enabled it to develop a solution to a real production problem. Moonshine Wars is an annual event that challenges employees to develop and prove out design and manufacturing solutions. At this year's competition, held in February in Seattle, teams from the 767 Program and Boeing Winnipeg shared the title of the event's co-grand champions. Their prize is a week-long seminar in Japan to strengthen their Moonshine skills. The term Moonshine is derived from the days of U.S. Prohibition, when individuals illegally made their own liquor, usually late at night. They used inexpensive materials; borrowed, adapted and made their own equipment; and adopted the best ideas and methods.
Moonshine is a practical application of the "use your wits, not your wallet" and "no excuses, just find a way to do it" kaizen philosophies to production equipment or facility design. Moonshine enables us to rapidly actualize our ideas through so-called "try-storming" and "card board engineering" to mock up and simulate quick-and-dirty solutions. But where do the ideas themselves which form the basis of these experiments come from? Preceding the moonshine step in the production preparation process is the concept development phase, which is where the world's greatest production engineer calls on nature's greatest engineers.
After determining the purpose of the design and defining the essence of the function, the Father of Moonshine would have us ask, "How would nature do it?" In essence this question requires us to return to seek wisdom from nature's greatest engineers and how they design creatures or systems which elegantly perform functions such as cling, shear, spin, protect or rotate. By gaining deep insights into how nature designs things, the theory goes, we can find simple solutions to our design challenges.
Based on that we sketch, combine, moonshine, evaluate, select and implement these ideas. That is the production preparation process in a nutshell. To learn more the production preparation process this article on how to use 3P to select design alternatives, an explanation of the so-called 16 catch phrases for lean manufacturing process design, and these typical top 5 reasons organizations choose to use 3P may be useful. If you have more specific questions or implementation needs, we are lucky to have quite a few experts on our team who have learned the production preparation process approach at Toyota or directly from Mr. Nakao so please feel free to get a hold of us.
Here is the TED video on nature's elegant designs.Comments are moderated to filter spam and inappropriate content. There may be a delay before your comment is published.