26 May 2021 Volume 28 -- 3P (Production Preparation Process)

The Production Preparation Process or 3P is the process of developing an integrated product and production system that will meet the requirements of product design quality at the necessary production volume at the target cost by the target date.

Unlike kaizens which are generally aimed at improving existing processes, a 3P event is essentially starting with a clean sheet of paper and utilizing lean principles from the inception of the project. Note that 3P can also be focused on just a process or product design but is more powerful when the 3P event couples the product and process from the start.

The 3P team members link the process hardware e.g., fixtures, materials, equipment, tooling, and tools to the process software e.g., material flow, information flow, standard work, and inspection, to provide an effective production system. The team incorporates lean concepts such as one-piece flow, Takt time, Poka-Yoke (mistake-proofing), Chaku-Chaku (Load-Load), auto-eject, ergonomics, quick-changeover, pull systems, TPM (Total Productive Maintenance), and avoidance of monuments.

3P can provide a sustainable, competitive advantage through a differentiated product design coupled with a differentiated production process. While competitors can buy a product and reverse engineer it to close a differentiation gap, it is much more difficult to reverse engineer the process that produced the product since it is hidden away in the company’s facility and production processes.

The 3P process should be used when:
● A new product is being developed
● An existing product is undergoing a significant re-design
● There is a significant uptick in demand
● A new plant is being built
● There are significant barriers in the existing product process that are limiting the company’s ability to meet customer demand effectively and profitably
● There is a need to create additional space in a facility
The 3P process should address Safety, Quality, Delivery (lead time intro to market date as well as lead time for serial production delivery to customers), Cost (product expense, capex, and working capital), and Growth.