Lean design 2

In continuous for last post for explaining lean design, here is more information for 3P which is the last stage of lean design process. The last stage is launch design and we always apply the lean tools of production preparation process (3P) to support the product launch to mass production.

The above drawing is the flow of the 3P and it included three steps, which are information phrase, creative phrase and redefine phrase. And the main objectives of the 3P are as below,

1. Design process with evaluate the alternative process choices,

2. Incorporate for mistake-proofing and just in time in process,

3. Build in the quality system in process,

4. Guarantee process capability, capacity and tact time,

5. Standardize the process.

Production preparation process event (3P event) is the improvement activity focus on the product development process. Mainly point to the preparation before pilot process. The focal points are material cost reduction, capacity evaluation, quality specification setting, and process flow and stations design and improvement. These are the topics included in the 3P event for your reference.

Day1:

- Team introduction,

- Lean principles training,

- Production preparation concept training.

Day 2:

- Goal and Scope definition,

- Product introduction,

- Review product development schedule,

- Tact time calculation,

- Components diagram and analysis,

- Review BOM and material cost,

- Review quality record of every process stations for both internal and external,

- FMEA setup and review with possible solution,

- Control plan setup and review

- Component reduction analysis and design fine tune.

Day 3:

- 7 proposals for main process station,

- Setup the assess specification and assess the 7 proposals,

- Simulate the best 3 proposals, observe the process and look for opportunities of improvement for process handling, fixture, mistake-proof, quick change over,...etc.

- 7 proposals for process flow and layout,

- Assess the 7 proposals for process flow,

- Select the best proposal,

- Fine tune the equipments.

Day 4:

- Finalize quality control plan,

- Fine tune the equipments,

- Pilot run evaluation, observe the material storage and process time.

- Documentation for tooling, fixture and process station design,

- Review FMEA, and possible solution,

- Final process at a glance,

- Fixture and equipment investment plan,

- Implement planning.

Day 5:

Team presentation for program result.

Hope you enjoy the information above, thanks!