The Lean 3P Advantage: A Practitioner's Guide to the Production Preparation Process Book

Lean 3P Design Concepts
What Is 3P?
Lean 2P Why Does 3P Work?
Separating R from D Horizontal Development Rapid Learning Differences between Traditional Product and Process Design, and Lean 3P Design Time Commitment of the Stakeholders

Lean 3P’s Place in the Product Development Process
Applying Lean 3P to New Product Development Voice of the Customer Case Studies Lean 3P within Existing Product Development Processes Phase-Gate Product Development Point-Based Engineering Set-Based Concurrent Engineering Set-Based Concurrent Design

Applying Lean 3P Design and Gaining Leverage
Introduction Concurrent Product and Process Design Using 3P Is One 3P Event Enough?
The Role of Operations Leverage Case Study Gaining Leverage The "Best" Time to Make Improvements The "Better" Time to Make Improvements The "Necessary" Time to Make Improvements

Getting Started
The Case for Change The Flow of a Lean 3P Event Information Innovation Prototyping and Rapid Redesign Optimization Key Participants in a 3P Event Space Required for a 3P Event Materials and Tools
3P Event Charter Pre-Event Orientation and Training Getting Started Recap

The Countdown and Overview of the 3P Event Week
Timing Considerations Preparing for a Lean 3P Event Two to Three Months Before One to Two Months Before One to Two Weeks Before The Day Before Overview of the 3P Event Week Day One Day Two Day Three Day Four Day Five

Kickoff, Charter, and 3P Goals
Kickoff The 3P Event Charter Introducing Lean 3P Design Goals Each Part, Each Interval (EPE or EPE I)
Summary of the 3P Design Goals Kickoff, Charter, and 3P Goals Recap

Product Planning and Process Evaluation Criteria
Product Planning Production Evaluation Criteria
3P Process Design Criteria Takt Time One-Piece Flow Pull System People Involvement Automatic Unloading Load-Load Operations Low-Cost Automation Mistake-Proof (Poka Yoke)
Minimal Capital Minimal Space Required Low-Motion Waste
100% Gauging Maximum Operator Value-Add Changeover Time Tool Room Maintenance Tooling Quality or Tooling Cost Safety, Ergonomics, and Health (and Possibly Security)
Environmental Impact Internal Waste Collection Simple as Possible Standard or Off-the-Shelf Equipment Process Capability Ratio (Cp)
Known Process Future Challenge Maintenance Free Technical Advantage Autonomation Development Time or In-House Development Scalability Flexibility Selecting the Evaluation Criteria Product Planning and Process Evaluation Criteria Recap

Defining Value-Adding Functions
Product Features and Process Steps versus Value-Adding Functions Product Considerations Process Considerations Evaluating Product and Defining the Value-Added Process Steps Concurrent Product and Process Evaluation Product Features and Process Step Value-Adding Functions Recap
3P Example—Kathryn’s Finest

Flow Diagrams, Developing Seven Alternatives, and Selection of the Better Three Alternatives
Flow Diagram Spaghetti Diagram Developing the Seven Alternatives from Nature Considering Industrial Alternatives Industrial Application of the Seven Alternatives from Nature Developing the Seven Alternatives Evaluation and Selection of the Top Three Alternatives The Pugh Method or Decision Matrix Summary of Progress Flow Diagrams, Developing Seven Alternatives, and Selecting the Better Three Alternatives Recap

Process at a Glance, Selecting Teams, Constructing the Three Prototypes
Process at a Glance Team Selection Safety Reminder Getting Started with the Three Prototypes Utilizing the Assigned Space The Need for Speed Researching New Concepts Identifying Risk Constructing the Three Prototypes Concept Viability Safety and Power Tools Process at a Glance Process at a Glance, Selecting Teams, Constructing the Three Prototypes Recap

Rapid Evaluation of the Three Prototypes, Selecting the Final Prototype
Introduction Rapid Evaluation of the Three Prototypes Evaluation Participants Process at a Glance and Complete Process Overview Congregate around the Prototype Being Reviewed Process at a Glance and Evaluation Criteria Take Some Pictures Selecting the Best Process Steps from the Three Prototypes System Impact People Impact Value-Adding Function Selection Summary of Progress Rapid Evaluation of the Three Prototypes, Selecting the Final Prototype Recap

Developing the Final Prototype, Incorporating Evaluation Criteria, and Measuring Effectiveness—Final Report-Out
Developing the Final Prototype Incorporating the Evaluation Criteria Add in the Transitions and Transfer Operations Measuring 3P Effectiveness Full Construction of Final Prototype Layout with Material and Tool Storage Identified Process at a Glance Calculation of Takt Time Assessment of Evaluation Criteria Assessment of Event Goals Final Cost Estimate Resource Plan and Teams Project Timeline with Milestones Spaghetti Diagram of New Operation Changeover Plan Review of Bucket-List Items and Action Items Final Report-Out Session Summary Developing the Final Prototype, Incorporating Evaluation Criteria, and Measuring Effectiveness, Final Report-Out Recap

3P Project Management, Potholes and Stumbling Blocks
3P Project Management Communication and Involvement A3 Problem Solving New Wine in Old Wineskins Out-of-the-Gate Performance Potholes and Stumbling Blocks Participant Selection Judges’ (Critical Evaluators) Selection Judges’ (Critical Evaluators) Role Participant Pairing Let It Breathe Time Management Leadership Set Big Expectations Believe in the 3P Process and Stick with It Postevent Expectations

Evergreen Lean 3P Design, Conclusions
Evergreen Lean 3P Design The A3 Process Applied to Small-Scale 3P Design Problem Statement Background Current Condition Goals Analysis Countermeasures Action Items Follow-Up Conclusions

Appendix
Flow Diagram of Lean 3P Design Process Lean 3P Event Charter Template Lean 3P Event Materials Checklist Lean 3P Pre-Event Activity Checklist Children’s Book Selections Potential Design Evaluation Criteria Potential Design Evaluation Criteria Checklist Seven Alternatives Template Seven Alternatives with Evaluation Criteria Template Process at a Glance Template Process at a Glance with Evaluation Criteria Template Works Cited and Bibliography

Index