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16 Catch Phrases of 3PBy Jon Miller - May 2, 2006 05:38 PM
My apologies for introducing a new term with out explaining it
yesterday. Thanks for askingBen. The 16 Catch Phrases of 3P are
used as guidelines for designing processes according toLean
manufacturing principles of JIT (Takt, Flow, Pull) and Jidoka. As a
result of asuccessful 3P workshop following the 16 Catch Phrases
the equipment and productionprocess you design should take you
closer to TPS.
The 16 Catch Phrases are:
1. Production preparation should be lightning fast. Avoid over
planning, use what youhave, act now.2. Build & layout equipment
for smooth material flow. Flow like a river, not like a dam.3. Use
additive equipment. Buy many speedboats instead of one tanker.4.
Build equipment that is easy to set up. Design in the separation of
internal and externaltasks.5. Make equipment easy to move. No
roots, no vines, no pits. Put wheels on everything.6. Use
multi-purpose equipment. Simple, "just fast enough" machines that
perform onefunction well.
7. Make operator work stations narrow. Town houses, not ranch
houses.8. Layout equipment for ease of operator movement. Remove
obstruction to smoothhuman motion.9. Eliminate wasted machine cycle
time. Design out 'air cutting' and minimize machinemovements.10.
Build equipment for small, swift flow lines. Enable Standard Work
(Takt, WorkSequence, SWIP).11. Use short, vertical flow lines.
Vertical = advancing process flow, horizontal =functional.12. Build
equipment for one-piece pull. Machine level. This is probably the
most criticalone.13. Build in quick changeover. Design in SMED at
the machine level.14. Link machines for smooth loading and
unloading. Line stops when WIP on the line is
"full work".15. Use multiple lines & rectified flows.
'Rectified' is an odd term, electrical engineers willget it.16.
Spiral upwards to jidoka. There are 5 steps to jidoka, which should
be pursued a stepat a time.
I may have gotten the sequence wrong. Looking over them again
more carefully, I thinkthere is a more logical sequence for
teaching these concepts. Each one of these simpleCatch Phrases is
not meant to be self explanatory, but a one-liner to remind you of
otherfuller Lean manufacturing disciplines such as SMED and jidoka.
This is how you designprocesses to fit Lean manufacturing with
3P.
These are a hodgepodge of machine or process-level guidelines
and flow or process-level
guidelines. I have seen them written down as 14, 15 or 20 catch
phrases. I learned these 16and they seem to capture the essence of
3P Lean equipment design. If you have found moreelegant ways to
phrase these in English, if you disagree with my explanation or
numbering,post a comment orlet me know.
Comments
Thanks for the explanation. I am going into a 3P event shortly
and will post these on thewall when I get there.
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