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
