The Lean 3P Advantage : A Practitioner's Guide to the Production Preparation Process book cover
1st Edition

The Lean 3P Advantage
A Practitioner's Guide to the Production Preparation Process

ISBN 9781439879115
Published March 23, 2012 by Productivity Press
336 Pages 67 B/W Illustrations

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Book Description

How do you take talented engineers and surround them with the elements needed to create brilliant designs that lead to market-changing products? Lean 3P is how.

Winner of a 2013 Shingo Research and Professional Publication Award !

Written from an operations perspective, The Lean 3P Advantage: A Practitioner’s Guide to the Production Preparation Process explains how to build collaborative thinking and innovation into the front end of the design process. Describing how to develop successful new products concurrently with new operations, the book illustrates real-world scenarios with numerous examples and case studies to help newcomers succeed the first time around. For those familiar with 3P, the book supplies the basis to explore Evergreen 3P—a process for applying 3P to small-scale design projects for similar benefits.

  • Details the 3P Lean Design process, explaining how and why it works so effectively
  • Includes case studies and examples of real-world applications
  • Presents time-tested methods based on the combined experience of numerous practicing companies

Coverage includes product planning and evaluation criteria, selection of alternatives, timing considerations, construction of prototypes, and measuring effectiveness. This book will help you and your team develop holistic designs that foster innovation and deliver products and production operations that effectively utilize people and exceed the expectations of all stakeholders.

Table of Contents

Lean 3P Design Concepts
What Is 3P?
Lean 2P
Why Does 3P Work?
     Separating R from D
     Horizontal Development
     Rapid Learning
     Differences between Traditional Product and Process Design, and Lean 3P Design
Time Commitment of the Stakeholders

Lean 3P’s Place in the Product Development Process
Applying Lean 3P to New Product Development
     Voice of the Customer
     Case Studies
Lean 3P within Existing Product Development Processes
     Phase-Gate Product Development
Point-Based Engineering
Set-Based Concurrent Engineering
     Set-Based Concurrent Design

Applying Lean 3P Design and Gaining Leverage
Concurrent Product and Process Design Using 3P
Is One 3P Event Enough?
The Role of Operations
Leverage Case Study
Gaining Leverage
     The "Best" Time to Make Improvements
     The "Better" Time to Make Improvements
     The "Necessary" Time to Make Improvements

Getting Started
The Case for Change
The Flow of a Lean 3P Event
     Prototyping and Rapid Redesign
Key Participants in a 3P Event
Space Required for a 3P Event
Materials and Tools
3P Event Charter
Pre-Event Orientation and Training
Getting Started Recap

The Countdown and Overview of the 3P Event Week
Timing Considerations
Preparing for a Lean 3P Event
     Two to Three Months Before
     One to Two Months Before
     One to Two Weeks Before
     The Day Before
Overview of the 3P Event Week
     Day One
     Day Two
     Day Three
     Day Four
     Day Five

Kickoff, Charter, and 3P Goals
The 3P Event Charter
Introducing Lean 3P Design Goals
Each Part, Each Interval (EPE or EPE I)
Summary of the 3P Design Goals
Kickoff, Charter, and 3P Goals Recap

Product Planning and Process Evaluation Criteria
Product Planning
Production Evaluation Criteria
3P Process Design Criteria
     Takt Time
     One-Piece Flow
     Pull System
     People Involvement
     Automatic Unloading
     Load-Load Operations
     Low-Cost Automation
     Mistake-Proof (Poka Yoke)
     Minimal Capital
     Minimal Space Required
     Low-Motion Waste
     100% Gauging
     Maximum Operator Value-Add
     Changeover Time
     Tool Room Maintenance
     Tooling Quality or Tooling Cost
     Safety, Ergonomics, and Health (and Possibly Security)
     Environmental Impact
     Internal Waste Collection
     Simple as Possible
     Standard or Off-the-Shelf Equipment
     Process Capability Ratio (Cp)
     Known Process
     Future Challenge
     Maintenance Free
     Technical Advantage
     Development Time or In-House Development
Selecting the Evaluation Criteria
Product Planning and Process Evaluation Criteria Recap

Defining Value-Adding Functions
Product Features and Process Steps versus Value-Adding Functions
Product Considerations
Process Considerations
Evaluating Product and Defining the Value-Added Process Steps
     Concurrent Product and Process Evaluation
     Product Features and Process Step Value-Adding Functions Recap
     3P Example—Kathryn’s Finest

Flow Diagrams, Developing Seven Alternatives, and Selection of the Better Three Alternatives
Flow Diagram
Spaghetti Diagram
Developing the Seven Alternatives from Nature
Considering Industrial Alternatives
Industrial Application of the Seven Alternatives from Nature
Developing the Seven Alternatives
Evaluation and Selection of the Top Three Alternatives
The Pugh Method or Decision Matrix
Summary of Progress
Flow Diagrams, Developing Seven Alternatives, and Selecting the Better Three Alternatives Recap

Process at a Glance, Selecting Teams, Constructing the Three Prototypes
Process at a Glance
     Team Selection
Safety Reminder
     Getting Started with the Three Prototypes
     Utilizing the Assigned Space
     The Need for Speed
     Researching New Concepts
     Identifying Risk
     Constructing the Three Prototypes
     Concept Viability
     Safety and Power Tools
     Process at a Glance
Process at a Glance, Selecting Teams, Constructing the Three
Prototypes Recap

Rapid Evaluation of the Three Prototypes, Selecting the Final Prototype
Rapid Evaluation of the Three Prototypes
Evaluation Participants
Process at a Glance and Complete Process Overview
Congregate around the Prototype Being Reviewed
Process at a Glance and Evaluation Criteria
Take Some Pictures
Selecting the Best Process Steps from the Three Prototypes
     System Impact
     People Impact
Value-Adding Function Selection
Summary of Progress
Rapid Evaluation of the Three Prototypes, Selecting the Final Prototype Recap

Developing the Final Prototype, Incorporating Evaluation Criteria, and Measuring Effectiveness—Final Report-Out
Developing the Final Prototype
Incorporating the Evaluation Criteria
Add in the Transitions and Transfer Operations
Measuring 3P Effectiveness
Full Construction of Final Prototype
Layout with Material and Tool Storage Identified
Process at a Glance
Calculation of Takt Time
Assessment of Evaluation Criteria
Assessment of Event Goals
Final Cost Estimate
Resource Plan and Teams
Project Timeline with Milestones
Spaghetti Diagram of New Operation
Changeover Plan
Review of Bucket-List Items and Action Items
Final Report-Out Session
Developing the Final Prototype, Incorporating Evaluation Criteria, and Measuring Effectiveness, Final Report-Out Recap

3P Project Management, Potholes and Stumbling Blocks
3P Project Management
Communication and Involvement
A3 Problem Solving
New Wine in Old Wineskins
Out-of-the-Gate Performance
Potholes and Stumbling Blocks
Participant Selection
Judges’ (Critical Evaluators) Selection
Judges’ (Critical Evaluators) Role
Participant Pairing
Let It Breathe
Time Management
Set Big Expectations
Believe in the 3P Process and Stick with It
Postevent Expectations

Evergreen Lean 3P Design, Conclusions
Evergreen Lean 3P Design
The A3 Process Applied to Small-Scale 3P Design
     Problem Statement
     Current Condition
     Action Items

Flow Diagram of Lean 3P Design Process
Lean 3P Event Charter Template
Lean 3P Event Materials Checklist
Lean 3P Pre-Event Activity Checklist
Children’s Book Selections
Potential Design Evaluation Criteria
Potential Design Evaluation Criteria Checklist
Seven Alternatives Template
Seven Alternatives with Evaluation Criteria Template
Process at a Glance Template
Process at a Glance with Evaluation Criteria Template
Works Cited and Bibliography


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Allan R. Coletta is a chemical engineer with extensive manufacturing operations, supply chain, and engineering experience gained while working in the chemical process and health-care diagnostics industries. His Lean experience started while serving as site manager for ICI Uniqema’s largest specialty chemicals plant in North America and continued to expand his role as Senior Director of Engineering for Siemens Healthcare Diagnostics. His passion for manufacturing and engaging people in continuous improvement continues to grow through personal application of Lean principles.

Allan serves on the Delaware Manufacturing Extension Partnership’s Fiduciary and Advisory Boards and is a member of the Delaware Business Mentoring Alliance. He is also a member of the American Institute of Chemical Engineers and the Association for Manufacturing Excellence (AME).


Finally, a go-to reference book on the important subject of 3P. Coletta does an outstanding job defining a step-by-step approach that can provide breakthrough results to manufacturing and service organizations alike.
Drew Locher, Managing Director, Change Management Associates

This how-to guide is filled with relevant examples that can help you apply the concepts and methodology to any product and process industry to develop higher quality products and processes delivered at lower costs.
Ken Rolfes, KDR Associates, Inc.

... an extremely valuable book for any practitioner interested in capturing the significant benefits of 3P for their firms. The author’s sincere desire to share his considerable knowledge with his readers comes through on every page.
Ron Mascitelli, PMP, President, Technology Perspectives