Many people asked me why some companies fails on Lean Enterprise implementation?
Obviously there are many reason why to fail, however, the companies that embrace
Lean Manufacturing and implement the 3P methodology are better positioned to succeed.
What is
3P? Production Preparation Process
Establishing an Appropriate Production System to Satisfy Requirements of
:
Product Design Quality for the Requirement Production Volume at the Target Cost by the Target Date.
Lean Enterprise consists of
physical items and defined processes to produce end products. You cannot buy your way to “worldclass” by
just purchasing the latest technology. We cannot just rely on outside
thinking but build on in-house
creativity that is not available to competition… to connect hardware to
software.
Fig
Slides from are courtesy of Shingijutsu training materials.
When 3P is used?
Fig
Why do 3P?
Short Term :
•
Deliver projects within ‘entitlements’
•
Time to Market, Time to Cost, Time to Quality
•
Avoid rework of line designs
Long Term :
•
Promotes rapid, quantum , out of box thinking in the
company
•
Try Storm and take Electronics Manufacturing to next
level
•
It’s a competitive weapon in our industry
•
Methodology
to solve company wide, segment wide, site wide problems
3P is highly effective weapon in the ‘ Battle for
Market Superiority ‘. Any technology that is ‘plug and play’ or ‘ready to use’
can also be purchased by competition. However items developed using 3P and
moonshine will have compelling value .
If 3P is not enforced in new designs , engineers then need to solve lot
of problems in the line leading to unending cycle of ‘rework’ to get to
standards established.
Fig
Where does
3P Fit In?
One must first practice Kaizen on factory floor to address waste in the
process. 3P focuses on entire process considering total cost, quality ,
delivery and stands on the shoulders of Kaizen.
If we don’t know how to kaizen , we would not be able to think of
Kaikaku.
Fig
The force behind 3P is to incorporate all elements of Lean Enterprise
into the design of products and processes. Unlike evolutionary process of Kaizen (Continuous
Improvement) , 3P must be revolutionary. The Japanese term for this is Kaikaku.
3P designs is a competitive secret weapon. They are not purchased but
moonshined and known only to World Class companies that develop the design on
their own.
Fig
Applying
the Principles of 3P Lean Enterprise
Without understanding of 3P and how it differs from traditional
approaches to product and process
design, many 3P projects may be questioned, criticized and shortened before
completion.
To be creative we must step outside the box and venture into things that
are ridiculous to untrained observer.
3P must be actively practiced and promoted. If 3P efforts do not keep
moving forward , they will regress. Along with this regression go the
competitive advantages and dollars spent
on discovering, creating and implementing the process
To assure that your company remains competitive, Kaizen Efforts (dashed
line) should be complimented with elements of revolutionary change or Kaikaku .
The solid line above explains how this will take us to Global Lean Enterprise.
Without periodic Kaikaku efforts, our efforts at continuous improvements will
be “too little, too late”.
As we hit plateau with Continuous Improvement, we get into cloud of uncertainty. This cloud blocks our view of our vision. 3P
propels us to break through this cloud. This is risky. Less than 10% will jump
into it. But 3P will take us to new level where Kaizen will begin with new
perspective. By doing this we renew our Kaizen enthusiasm with new direction
and vigor.
Fig
3P Process Steps
There are several variations in 3P process steps. The following five step process are
intended to give summary level understanding of 3P.
Fig. Fig Fig
I hope this help you on your next project.
