Unleashing the Power of 3P

Dan McDonnell does a great job of sharing all the key points needed for a 3P transformation. He emphasizes the holistic approach to 3P - it is much more than 7 ways or scale cardboard models. The narrative style makes it an easy read. I am not sure that it is a standalone reference for launching 3P in your company - but it is a must read for anyone open to making a lean breakthrough using 3P. The tools shown really do work and together can help drive breakthrough improvement...

The authors tried to write their version of "The Goal" or "Who Moved My Cheese" but failed to really make a narrative that was worthwhile.For the true Lean practitioner, a short skim of this book is all you need.For someone totally unaware of Lean, this could be dangerous.

This is an important book on a topic that needs a lot more teaching and explanation. The reader will get a comprehensive understanding of the whole 3P process and the potential benefits. Love the checklists and visual guidelines for the 3P process.

High school level material. Waste of time and money.

For those dealing with new facility start ups, plant expansions, product development projects, product transfers between plants, major changes in product design, demand or plant re-arrangement; who need to achieve full operational capability on day one while reducing capital expenditures and target product costs.Using the example of saving a plant losing money and customers, facing sale or relocation to a lower cost region, this covers how the Production Preparation Process can achieve a Vertical Start Up meeting schedule, cost and quality targets on launch.Points include:- What you don’t see- Simulating the work; Operators as surgeons; The internal customer- Moonshining practice, characteristics in selecting employees for this, and how this can often save 30-50% on plant and equipment capital expenditures.- How manual recording of information creates a more intimate ownership for the team, and a higher level of commitment to and the knowledge of why it’s there and what it means.- Visually supported depiction of the dos and don’ts of manufacturing, which may be the opposite of how we have tended to design our processes.- Staffing 3P- 20 principles of manufacturing to adhere to throughout the process- The amount of capacity to plan for, and when planning beyond that is a waste.- The “Sequence 90” concept- The 7-Ways Process and its steps- How bench top mock ups enable people to further perceive problems and wastes in the design phase and what to consider while going through this- An example of getting a rework back into flow without disrupting line performance.- Rule of 10’s, and how much more costs can be when discovered by the customer.- In deciding what to work on, selecting what gets a full scale mock up.- What ERP systems are no longer used for, and Master Scheduling with manual functionality to increase responsiveness to last minute changes.- Developing a PFEP (plan for every part), parts segmentation, inventory system design, replenishment planning and a Supermarket Evaluation Checklist- Working with human resources develop a hiring model supporting required training including actual pre-production units to meet production requirements on day one

This is a great book for someone to learn in more depth about using 3P to get out of the box and evaluate a new way to improve a process to the next level. The method is explained in detail with visual examples.