3P培训

1BuildingQualityintotheProcessPROCESS3P3PDoer’sTrainingManualProductionPreparationProcessWhatIs3P?•ProductDesignQuality•RequiredProductionVolume•TargetCost•TargetDateMembersaretheLinkforBuildingInQualityFixturesMaterialsEquipmentMachinesToolsMaterialFlowJustInTimeStandardWorkProductionFlowProcessProductionPreparationProcessBuildingQualityintoOurProductionSystemApplyingthePrinciplesRapidContinuousImprovementSimple/FlexibleU-ShapedCellsOne-Piece-FlowErgonomicsTaktTimeHanedashiChaku-ChakuJidokaWasteEliminationPoka-YokeThe3PprocessrequiresustouseDEVELOPEFFECTIVEDESIGNSANDPROCESSESIT’SACOMPETITIVEWEAPONINOURINDUSTRYPROMOTESRAPIDCONTINUOUSIMPROVEMENTWhydo3P•NewPlantIntroductions•ChangesInDemand•ProductDesignChanges•NewProductIntroductionsWhenis3PusedProductionPreparationProcessBuildingQualityintoOurProductionSystemQualityQuantityCostTiming“BuildsAppropriateQualityintotheProductionProcess”“HighlyFlexibleandAdaptableProcessesandEquipment”“FocusonReducingBothCapitalCostsandProductCosts”“NewProductsorIncreasedProductionisDeliveredONSCHEDULE”ProductionPreparationProcessBuildingQualityintoOurProductionSystem1.Machines/Equipment2.Tooling3.Layout/FlowOurOldWayofThinkingAboutCreatingaProductionLine/CellProductionPreparationProcessBuildingQualityintoOurProductionSystemTheNewWayofCreatingProductionLine/CellTheNEWWayofCreatingProductionLine/CellNakao’sSeven(7)Flows1.FlowofPeople2.FlowofRawMaterial3.FlowofParts4.FlowofProducts5.FlowofEquipment6.FlowofInformation7.FlowofEngineeringAllofthesemustbeevaluatedProductionPreparationProcessBuildingQualityintoOurProductionSystemProductionPreparationProcessBuildingQualityintoOurProductionSystemCurrentDesignOrNewDesign(Preliminary)SignYourContractsBreakdownProductintoitsPartsDetermineFunction(s)(1)WhatareKEYWords(2)FindExamplesinNaturalWorld(3)SketchandPostTheseExamples(4)SketchBackground(5)CombineIdeas-CreateDesigns(6)PostDesignsGroupbySimilarity(7)ManufacturingProcessPrep.ProductDesign3PConstructPrototypesMOONSHINE(8)PresenttheDesignsSelectBest3(9)KeepMoonshiningGatherData(10)HoldTrialSelectTopDesign(11)DesignorRedesignofPartProductionPreparationProcessBuildingQualityintoOurProductionSystem1.DetermineFunctionWhatistheTheme&ScopeofYourEventFUNCTION1.Point3P2.Line/Cell3P3.Plant-Wide3PPostonWall/BoardResisttheUrgetoExaminetheExistingProcess.ThiswillonlyCreateaBiasandStifleCreativity.ProductionPreparationProcessBuildingQualityintoOurProductionSystem2.DefinetheEssenceoftheFunctionWhataretheKeyWordsKEYWORDSGuideTurnDrillRollClampRigidityShearSwivelFastenSpinBrakeSlideOscillatePressLockBondDrawaSketchthatBestDescribesWhat’sHappening.ProductionPreparationProcessBuildingQualityintoOurProductionSystem3.LookforExamplesofKeywordinNatureNaturehasspentmillionsofyearsrefiningthesephenomena.ResistAllAttemptstoUseManMadeExamples.Nature’sExamplesareOftenSimpleandPure.SpinMoveEncapsulateSeparateStingGripClingAdhereShearCrawlBuoyHingeProductionPreparationProcessBuildingQualityintoOurProductionSystem4.SketchExamplesandExamineWhatisHappening.GroupCommonExamplesSketchtheExamplesDoYourHomeworkExamineinDetailYouMUSTLookDeepintothePhenomenontoUnderstand.WhatMustTakePlaceforThisPhenomenontoHappen?AttachHingeGroupCommonExamplesProductionPreparationProcessBuildingQualityintoOurProductionSystem5.SketchBackgroundandConditionsofFunctionYoumustUnderstandHOWtheNaturalPhenomenonOperatesFromThis:Remember!YouareUsingYour12YearOldMindset.ToThis:105degreesrotation48～94degreesflexForceuniformSocketLiningProductionPreparationProcessBuildingQualityintoOurProductionSystem6.CombineIdeasfromNature---CreateDesignSketchesDevelopatleastSevenDesignSketchesbyeachTeamMemberFlyBeCreative.DoNOTBeAfraidProposeAnything!SevenProposalsProductionPreparationProcessBuildingQualityintoOurProductionSystem7.CombineSimilarDesigns.Pick7MethodstoBuildPrepare“ProcessAtAGlance”SheetbeforeBuildingProposals.7DesignsUseReadilyAvailableMaterialsToBuildYourPrototypes.DoNOTMakeThisStepOverlyComplex.MoonshineProductionPreparationProcessBuildingQualityintoOurProductionSystem8.ConductExperimentsandTrialstoCollectRealDataHowdoeseachdesignperformagainstourcriteria?CollectRealDataDocumentTheDataEvenThoughYourModelisNOTPerfect,ItwillGiveYouValuableDataonHowtoIMPROVEYourDesign.ProductionPreparationProcessBuildingQualityintoOurProductionSystem9.SelecttheThreeBestDesignsBaseonCriteria,then...ConductmoreMOONSHINEontheTOP3Designs.DesignDemo/ExplainDesignDesignEvaluationYouMUSTUnderstandtheQualityRequired.KeepThinking…”Dimensions,Tolerances,andGauges.”ProductionPreparationProcessBuildingQualityintoOurProductionSystem10.GatherandEvaluateDataonTop3KeepMOONSHININGandImproveDesign.IfProblemsArise...FixThemRightontheSpot,Don’tTalkAboutThem.KeepTRY-storming…NotBrainstorming.ProductionPreparationProcessBuildingQualityintoOurProductionSystem11.BringTogethertheFunctionsSelecttheBESTDesignProposal#1QualityManf.EngineeringProductDesignPurchasingProductionHealthSafetyMachineDesignManagementToolingDesignEvaluateCommitteeHaveModelsandDataPreparedforViewingByEvaluationCommittee.Final