Production Preparation Process ( 3P) - version 2.

Production Preparation Process ( 3P)

培訓手冊
The information covered in this manual contains proprietary 3P
concepts from Shingijutsu Co. with their permission. This manual is the
property of Johnson Electric and shall be used inside the company only.

此手冊信息为经新技术公司许可而总结的其私有3P概念。此手册所有
权为德昌电机，信息仅为公司内部使用。

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JE’s Vision: We are the growth company in motors and related businesses.
Come Grow with Us.
LEGEND: Delta CVA
[PO] = Perspective Owner Generate US$144m Delta CVA in 3
(TO) = Theme Owner Years CVA > 65% of OP (PT)

Financial Revenue Growth Profit Growth 20/20 Vision Asset Management

Perspective Organic, increase sales to Increase OP% from Improve total OH% from Improve ROCE from
US$1.3 Billion in Yr 3 16% to 23% 31% to 20% in Yr 5 (25% in 17% to 34% (TS)
[PT] (CMG:DI ; AUTO:MD) (CMG:DI ; AUTO:MD) Yr 3) (JF)

Improve Customer
Customer Increase Market Share Improve JE Image Improve Value Proposition
Relationship Mgmt.
Perspective Market share from Equal technology Whole product differentiation and
Increase customer share,
7.3% to 10.8% perception of major margin improvement for extended
[JD] growth rate and retention
(JD) (JD) (RW) product offerings (JD)
competitors

Technology New Strategic Industrial

Internal Resource Deployment JCIP Outsourcing
Management Processes
Perspective Make / buy / use of - World class mgt. team Corporate projects Building service
RP, SP, BSC, NF
technology to yield - Mgt. continuity to drive business competency
[JF] to support sales & - Change/perform’ce - technical
30% new product and process
profit growth culture (HH) improvements - manufacturing
revenue
(KC) (JF) - Strategic compensation (EB) - supply (JF)

Employee Development
Leadership Organizational Learning Knowledge Management & Retention
Learning &
Growth Behavioral competency -Learning organization Retain high calibre talents
development and strategy Centralized knowledge source
Perspective - LMS by creating growth and
awareness across JE to manage. leverage and
- Mini- Crotonville learning opportunities, and
[PW] transfer competencies.
(HH) - ARCI (HH) (HH) recognition (HH)

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JE的遠見: 在马达和相关商务方面擴展的公司
LEGEND:
[PO] = Perspective Owner Delta CVA
(TO) = Theme Owner
Generate US$144m Delta CVA in 3
Years CVA > 65% of OP (PT)

收入增长 利润增长 鸿图远见 资产管理

商务远景 市场份额从7.3%到 市场份额从7.3%到 提高ROCE從17%增加
从16%增長到23%
[PT] 10.8% 10.8% 到34%

市场份额 提高JE形象 提高客户关系管理 改善盈利结构

客户远景 市场份额从7.3%到 在技术和知识产业方面赶 使产品系列多样化并提
上竞争对手 增加客户份额保持增长率
10.8% 高利润

技术管理 新战略程序 资源支出 JCIP 外发

国内远景
世界級管理組 增强服务能力从以下三方
新产品收入的30% RP,SP,BSC,NF 合作項目驅動 面: 技术上
連續管理;
[JF] 用于购买和使用技 支持销售&利润 商務和程序的 生产上
改變/效率文化
术 增长 提高 供应上
戰略賠償

领导阶层 组织学习 知识管理 职员保留與发展

学习和成长 學習組織
远景 能力行為發展和策 LMS 創造成長及學習的機會,
集中資源知識管理 來保留有高質素的人才,
[PW] 略 Mini-Crotonville
-ARCI 并重視他們

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Breakthrough Thinking vs Standard Approaches

創造性思維的標準方法
JCIP

Breakthrough Strategy
創造性策略
Standard Approach
標準方法
Improvement
-Trained & Dedicated Individuals
訓練有素及敬業的員工 •Current Tools 靈活性的工具
- Analytical Expertise >70%
• Kaizen 改善
Improvement per Project •Lean Manufacturing 精益生產
-通過專業性分析來使每個項目的改 •Re-engineering 重整工程
善達到70%以上 •Typical TQM 典型全面質量管理
-

Time in Years
1 2 3 4 5
BUT the speed is the difference !!!
Organization sees improvement
但速度不同!!!
組織改善

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Comparison of number of Engineering changes in 3P design concepts versus present design methods
对照与3P理念相对的目前的设计方法来看工程改变的数量

No. of Engineering Changes Present method

工程改变数量 3Pconcept s applied
目前方法
3P理念的应用

Time

Design & Development

stage Mass Production stage
设计和开发阶段 批量生产阶段

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Introduction 简介
 3P is one of the JCIP breakthrough strategies to improve productivity and reduce costs.
3P是JCIP提高生产力，减少成本的突破性战略之一。
 Production preparation is a process whose purpose is to develop an appropriate “production system” in the
shortest time possible to satisfy:
Production preparation是一项工程，其目的是要求在最短的时间内开发出适合的
“生产系统”，并可满足：
 Design Quality Requirements 设计品质要求
 Production Requirements 生产要求
 Cost requirements 成本要求
 “Production System” refers to not only machines / fixtures / hardware but also software
such as people, inspection, maintenance and materials planning and handling.
“Production System”不仅包括硬件:机器/夹具，而且包括软件：人，检查，维护及材料计划和处理
 The key concepts of 3P are:
3P的关键概念包括：
 Concurrent product design engineering, machine and fixtures design process.
同步进行的生产设计工程，机器和夹具设计过程。
 Simple and low cost machines and fixtures to meet required production takt time.
可达成生产TAKT TIME要求的简单的，低成本的机器和夹具。
 Small flow line with longer takt time to enable use of low cost machines and fixtures.
用较长的TAKT TIME，使用低成本的机器和夹具便可运转起来的小型生产线。
 Use mock up models to improve machine and fixtures designs.
通过制作模拟模型来改善机器和夹具的设计。

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What is 3P ? 什幺 是3P？ Important points:

Every step is important.The goal isn’t only to
products and machines / fixtures. The goal
 3P is abbreviation for Production Preparation Process. is to design and build quality products that
3P是Production Preparation Process 的缩写。 can be manufactured at the lowest cost and
level of conformity.
 Establish a production system to satisfy the requirements of: Consider the manufacture of the product
during it’s prototype design stages.
建立生产系统满足下列要求：
If we do not, we will fall back to the old ways
we always have manufactured things before.
 The goal isn’t only to design products
 Quality 品质 Product Design Quality
要点：
产品设计品质 * 每一步都是重要的
 目标不只是去设计产品，机器/夹具，
而是设计出制造最低成本，最符合
Required Production
 Quantity 数量 要求并可保证质量的产品。.
Volume 要求的生产量  在原型设计阶段就要考虑产品的制造
若非如此，我们就会一直局限于我们
从前的做事方式。.
Target Cost
 Cost 成本 目标成本

Target date
 Timing 时间 目标日期

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Why do 3P ? 为什幺作3P？
Production preparation process supports the Breakthrough Improvement and JIT principles of lean manufacturing:
Production preparation process支持突破性改善和简约制造JIT原则：
 Quality 品质：
Building appropriate quality into the process 在每一道工序里面构筑适合的品质
* Develop component design with ease of manufacturing and assembly.
改善组件设计来达成制造和装配简便。
* Develop machines and fixtures capable of meeting the process requirements.
改善机器和夹具能力来符合工序要求。
 Quantity 数量 :
Establish machines and fixtures that must permit swift response to increases and decreases in production demand.
使机器和夹具能力可随生产量增减的要求来适当转换。
* Develop machines and fixtures to match the production takt time.
开发可满足生产TAKT TIME要求的机器和夹具。
 Timing 时间：
Shorten production preparation lead time 缩短生产准备LEAD TIME
* Lead time compression is accompanied by simultaneous product development and
machine / fixtures planning and development.
LEAD TIME压缩与产品开发，机器/夹具计划和开发同步进行。
 Cost 成本：
Profit = Selling price - Cost 利润 = 销售价格 - 成本
* In a competitive market, price is set by the customer. We must lower cost to maintain profit.
市场竞争激烈，价格由客户确定。我们必须缩减成本来获取利益。

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When is 3P used? 何时用 3P？

New Plant Introduction
新 制 造 厂 开 办

Changes Product
in Production Design
demand Preparation Changes
产量要求 Process 产品设计
变更时 变更时

New Product Introduction

新产品介绍
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Manufacturing Process Preparation Flow

List and Review the Layout the Parts Begin Processes at a Develop the 7 Ways
Construct the
Process Steps Fishbone Chart Glance Sheet For each process, everyone
Design If parts are available, lay sketches seven different
Breakdown the process them out as they would On the first row of this ways of doing that process
Process steps required to process
Show pictorially how the appear at the various sheet, sketch the part on the 7 Ways Chart.
part is transformed at each process steps. If new part,
the material. Think basic appearance at each step of These must be detailed
3P processes NOT existing
process step. Again think
post process drawings or process. These should be enough to understand at a
basic process steps prototyped parts
processes similar to the Fishbone Chart glance

Construct Design Select the Top 3 or 4 Present and Evaluate Complete 7 Process
Proposals the Processes at a Glance Sheets Post, Group and
Construct prototypes of the
top 3 designs. These For these 7 proposals
Narrow Selection
functioning models should From the evaluation, select Present the PAAG sheets devise & sketch methods to After all the 7 Ways sheets
be complete with poke the top 3 or 4 design and have everyone evaluate assure quality via poke- are completed, post and
yoke and hanedashi proposals. Do not overlook the 7 proposals based upon yoke or No-Go gage. group similar ideas. Then
vote to narrow selection to
devices. Do not think attributes of non-selected the evaluation sheet Sketch tool, Jig/fixture and the seven best ones.
machines yet designs that scored well criteria. hanedashi

Simulate Process Display and Evaluate

Refine Process at a Select the Best Design Start Equipment
Conduct Moonshine
Glance Sheets Number and display Determination
Testing of the designs Again using the criteria
through process simulation. designs with PAAG sheets
sheet, select the best design Layout the fixtures, jigs,
Collect data and video Update with changes made to others. Evaluate criteria
again looking at high parts, etc on a table and
process. Follow the steps during the MOONSHINE sheet. Evaluate each
scoring attributes of the begin to determine
used in Process at a Glance exercise. independently and not
non-select designs. machinery requirements.
Sheet against each other.

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Manufacturing Process Preparation流程

开始Processes at a 开发7种方法
列出并回览工序步骤 构造鱼骨图 零件布局
Glance Sheet 针对每一道工序，每人
设计工序 依据装配件分解工序
通过图画了解每一道
如已有零件，将其放于
在7 Ways Chart上草图画
工序后零件的变化。再一次 在此表第一行，草图画出 出此工序的7种不同做法。
3P 步骤。考虑基本的工序，
而不是已有工序。
考虑基本的工序步骤。
工序步骤上。如为新零件，
张贴工序图纸或模拟零件。 每一工位的零件 必须足够详尽，可以
形状。应与鱼骨图类似。 一览便知。

完成7 Process
构造设计 选择3或4个最好的建议 at a Glance Sheets 张贴，分组，缩小
介绍并评价工序 选择范围
构造3个最好设计的模板。 评价后，选出3或4个 介绍PAAG sheets， 针对7个建议，设计，草图
这些结构模型应使用poke 最好的设计建议。但不要 全员依据评标准来评价 画出方法使产品经由猪仔模 完成7 Ways sheets后，
yoke和hanedashi 或No-Go gage来 张贴并分组类似的创意。
忽略未选择的 7个建议。 然后，投票缩小选择范围，
devices。先不要考虑机器。 但评分好的建议。 保证品质。草图画出工具， 选出7个最好的。
夹具和HANEDASHI。

展示并评价 选择最好的设计
模拟工序 开始确定设备
精炼PAAG Sheets
实施Moonshine，通过工序 编号并展示PAAG sheets
再一次，用评价标准单， 在桌子上布局夹具，零件
模拟来测试设计。 的设计给其他人。
更新MOONSHINE练习过程中 选出最好的设计，同时 等，
收集数据并录制工序。 评价尺度单。独立
引发的变更。 也要参考评分高单未被选择 开始确定机器要求。
依照PAAG的步骤进行。 评价每一个方案，
的设计。
不反对彼此的方案。

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Current Design Sign Your Breakdown Determine What are KEY

Or New Design Contracts Product into its Function(s) Words
(Preliminary) Parts (1) (2)

Post Designs Combine Ideas- Sketch Sketch and Post Find Examples
Group by Create Designs Background These in Natural
Similarity (6) (5) Examples World
(7) (4) (3)

Present the Keep Hold Trial Design or

Construct
Designs Select Moonshining Select Top Redesign of
Prototypes
Best3 Gather Data Design Part
MOONSHINE
(9) (10) (11)
(8)

Manufacturing
Process Prep.

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签合同 分出产品 确定功能 什么是关键

目前设计或 的各个零件 字
新设计 (1) (2)

据相似性进 进行创造性 草拟背景 用草图的形 在自然界中

行设计分组 思维设计 式确定例子 找到例子
(7) (6) (5) (4) (3)

凭想象创建 从目前设计 在此基础上 选取三种最 零件的设计

原型 中选取三种 收集资料 好的设计进 或再设计
MOONSHINE 最好的设计 (10) 行试验
(8) (9) (11)

生产过程
准备

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1. Determine function 确定功能

What is the theme & scope of your event 你的事件的主题和范围是什么

FUNCTION
Notes
1. Point 3P
3P点
2. Line/Cell 3P
3P线/单元
3. Plant-Wide 3P
厂范围的3P(西)

Post on Wall/Board
Resist the urge to examine the existing process
墙上/板上张贴
This will only create a bias and stifle creativity.
抵制紧急检查目前的流程，这只会引起一种偏见, 并会抑制创造力

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2. Define the essence of the function定义功能本质

What are the key words关键是什么

Guide指南 Clamp夹钳 Swivel 转环 Oscillate 振动

Turn 转动 Rigidity 刚度 Spin 旋转 Press 压

Drill 钻子 Roll滚动 Brake闸 Bond联结

Shear 剪切 Fasten 拴紧 Lock锁 Slide 滑

Key words 关键

Draw a sketch that best describes what’s happening.

画一幅能最好描述的草图所需的关键

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3. Look for examples of keyword in nature在自然界中寻找关键字的例子

Nature has spend millions of years refining these phenomena大自然已经存在这些现象成千上万年了

Shear
Attach Cling
Spin旋转 Move移动 钳
使附属 粘紧

Encapsulate Separate Crawl

Adhere
压缩 分离 Grip紧握 爬行
粘附

Resist all attempts to use man made examples.

Nature’s examples are often simple and pure
抵制所有用人做的例子，大自然的例子通常是简单而又质朴的
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4. Sketch examples and examine what is happening.

草拟案例观查发生的情况
Group common examples
对相同的例子进行分组 Do your homework
做你的作业

Hinge
Attach
附上 铰链

Sketch the examples

Examine in detail
草图例子
观查细节

Group common examples

对相同的例子进行分组
You must look deep into the phenomenon to understand.
What must take place for this phenomenon to happen?
对现象进行深入观查并加以理解这些现象的发生会造成什么情况的发生
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5. Sketch background and conditions of function

草图背景和功能情况
You must understand how the natural phenomenon operate
Socket lining
你必须明白自然现象是怎样活动的
窝内层

From this: To this:

105 degrees rotation
105度旋转

48~94 degrees flex Force uniform

48-94度弯曲 用力均匀
Remember! You are using your 12 year old mindset.
记住!你要用12岁的思维方式
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6. Combine ideas from nature--create design sketches develop at least seven design
sketches by each team member
从自然中结合想法,创建设计草图, 由每个组成员至少画出7张设计草图

FLY

Seven proposals七种提议

Be creative. Do not be afraid propose anything!

有创造力,不要害怕提出建议

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7. Combine similar designs. Pick 7 methods to build. prepare “process at a glance” sheet
before building proposals
结合相似的设计,选择7种方法去建造模型. 在做提议之前准备“构思评分表”程序.

7Designs

七种设计

Moonshine
默默耕耘

Use readily available materials to build your prototypes.Do not make this step overly complex.
快速地使用可利用的材料去建造你的原型.不要使这步过于复杂化.

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7. Conduct experiments and trials to collect real data. How does each design perform against our
criteria?
实施试验并试用收集的真实的资料,與我們的標準相對的是怎樣執行每一個設計.

Collect real data Document文件

收集真实的资料

The data 资料

Even though your model is not perfect, It will give you valuable data on how to improve
your design.
虽然你的模型不完美,但它会给你提供怎样改善你的设计的有价值的资料

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9. Select the three best designs base on criteria, then…

Conduct more Moonshine on the top 3 designs.
在标准的基础上选择三个最好的设计,然后 Top 3 Design
三种设计
在最好的三种设计上自己再进行Moonshine(模拟)

Established 1 2
criteria 确定标准
3
Design

Demo/Explain
design Design
演示/解释 设计 evaluation
设计评估

You must understand the quality required.

Keep thinking… “dimensions, tolerances, and gauges.”
你必须理解质量要求.一直思考“尺寸，公差,和基子的测量方式

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10. Gather and evaluate data on top 3. keep MOONSHINING and improve design.
在三种最好的设计上收集并评估资料

If Problems arise… Fix them right on the spot, don’t talk about them.
Keep Try-storming…Not Brainstorming.
如果问题出现… 立即解决问题,不要 多谈空论(身体力行)
坚持TRY- storming,而非Brainstorming
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11. Bring together the function select the Best design

选出最好的设计

Quality 品质 Others其它
Manf. engineering 制造工程 Machine design
Product design产品设计 机器设计
Purchasing采购 Tooling design
Production生产 工具设计
Sales 销售
RCI

Have models and data prepared for viewing by evaluation committee. finalize design and
start pre-production Kaizen process.
准备好模型和资料,提交评估委员会进行评估.最后确定设计方案并开始预生产改善过程

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No ONE-WAY Machines No Dinosaur Machines

不要单向机器 不要恐龙型机器
Bring the part back to the operator We know what happened to the dinosaurs
把零件送回给操作员 我们知道这些恐龙发生了什么(恐龙灭绝)

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Sacred Cows make the BEST Burgers

正如最好的牛不一定能做成最好的漢堡一樣,
最好的材料不一定能做成最好的产品

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Use Equipment Necessary to Permit One Unit Flow

使用必要的設備, 一只流生产

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Use Ideas NOT Money

使用智慧而非金錢

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Don’t Build Big Ships with Big Guns… Think Small and Responsible
不要造大而笨重的大船,而選擇小而適用的快艇

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Keep height of all Items in the Workplace Very Low

工廠的所有物品的高度都保持低高度(眼到手到)

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Explanation NOT Necessary

沒必要解釋,只是做自己做的事(少说多做)

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Batch Production VS. One Piece Flow

一只流生产
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1. Production Preparation should be lightning fast.

生产准备应该越快越好

Conception………………..Production
观念 生产

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2. Equipment construction and line layout (U-cell) should permit easy material flow. Layout of
process sequence should be counter-clockwise (right to left direction flow).
设备的构造和生产线的设置(U形)应该让原材料灵活流动. 生产工序应该是逆时
针方向移动(从右到左)

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3. Build additive equipment. No battleships

建立附加的设备,而不需要象战舰一样庞大的设备
舰 舰舰

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4. Build equipment to allow easy changeovers.

建立可以容易轉型號的設備
Change-over Flowing Gap New Product
Old Product
轉型號的流動的缺口 新產品
舊產品

5 4 5 4
A 3 F 3
2 1 2

5 4 5 4
3 E 3
B
11 2 1 2

5 4 5 4
C 3 D 3
1 2 1 2

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5. Make equipment easy to disconnect and relocate.

使設備灵活拆開并重新安置

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6.Make versatile equipment that can easily be reconfigured.

製造多用途的設備能夠較灵活地被重新裝配

Big Dedicated
Machines
拆除大而專用的設備
Not Live Slaves
不要成为大设备的奴隶

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7. Make operators stations narrow. Deep is acceptable

安排操作員位置變窄,操作員位置較長是可以接受的
Ranch 大牧場
Style 風格
Layout佈局
Wide and Shallow寬而淺

Principle of
Townhouse
Verticality
城市建築
垂直狀態原理
Style 風格
Reduced Footprint
Layout佈局
減少足蹟 Narrow but Deep窄而深
Reduced Walking減少步行
1step-station to station(操作员位置间距为1步)

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8. Both the equipment and layout should allow the operator to move easily.
Open room concept allows operators to see the big picture.
設備和设置(生产排拉)應該允許操作員容易地移動.開放的空間觀念使操作員視野更開闊

Fixed
Layout

固定的设置

Standard work may be changed to for

increased demand without changing layout
因為增加了要求而沒有改變设置,標準的工
作可能被改變

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9. Eliminate machine waste. Kaizen the motion of the machine.

排除機器浪費.改善運作
1. Switch on接通
2. Air cutting down (Muda)
削減空中向下行程(浪費)
3. Drilling(轉動)
4. Air cutting up (Muda)
Air 削減空中向上行程(浪費)

cutting MUDA 浪
費

Only this part adds VALUE

只有這部分運作有增加價值
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10. Build equipment to fit into small swift vertical flow lines.
建立小而靈活的生產流水線設備,而不要大而笨重的單向的設備.

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11. Eliminate horizontal flow. This creates a batch processing.

排除水平流動,建立一個分枝流程

Horizontal
PRES PRES PRES PRES
S 衝壓 S S S Handling
NO FLOW

Weld Weld Weld Weld

銲接

Paint Paint Paint Paint

噴漆

Assy. Assy. Assy. Assy.

裝配

A B C D
Products產品

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12. Production should be pulled along at Takt time.Do not allow room or capability for batching.

生產應該前拉式,而不允許成批生產(不應該後推式) One
Per
Day

Don’t Produce 7 units once per week

when the customer wants 1 per day.

當顧客每天想要1個的時候,每周不要一次生產7個

1 1
day day

Takt Time = 1 Day

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13. Build tooling/machines for rapid setups and quick changes.

建立機床安裝/迅速設置并調整機器

Ease of
positioning
靈活地移動位置

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14. Link machines to make work flow smoothly and avoid excessive WIP
連結機器使工作平滑流動并避免半成品過多

One

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15. Use multiple lines to avoid constructed flow.使用多重線路并避免構造的流動

模型 F1 A1
Model A B1 F2
Model B P1 A2
Model C B2 F3
Model D A3
F4
Use Multiple and Rectified flows
使用多重線路并改正流動
Model A B1 F1 P1 A1

Model B B2 F2 P2 A2

Model C B3 F3 P3 A3

Model D B4 F4 P4 A4

B = Blank空白 F =Fabricate製作 P =Paint噴漆 A=Assembly裝配

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16. Continue pursuing the steps of Jidoka by spiraling upwards continuously

separating machine tasks from human tasks.
繼續實行螺旋向上不斷將人工任務轉成機器任務的設備生動化的步驟

Jidoka
7 Quality Check (Poka-Yoke)品質檢查(猪仔模)

6 Part Removal (Hanedashi)(自动吐出)

5 Autonomation of Returns自 化返回

4 Automation of Stops自動停止

3 Autonomation of Feed 自 化進料

2 Automation of Holding自動支持
1 Autonomation of processing自 化流程

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