Definition
Eliminate waste through product-process synchronization, and rapidly create and validate manufacturing preparation tools for product and process programmes with minimum time/material/capital.
In detail
Production Preparation Process (3P) is a manufacturing preparation tool that emphasizes considering the process simultaneously during the product design phase. Through cross-functional team collaboration, it quickly creates and validates product and process solutions with minimal time, materials, and capital. It addresses the waste and rework caused by the disconnect between design and manufacturing when introducing new products or processes. Unlike conventional project management, 3P focuses on eliminating waste in design, not just managing schedules. Its outputs are typically validated process plans, a vertical launch ("vertical take-off") plan, and key performance indicators — the goal is to hit target the moment production starts, skipping the ramp-up period entirely.
Example in practice
When a company plans to launch a new model of equipment and customers have strict delivery cycle requirements, teams from engineering, production, procurement, etc. can jointly participate in 3P activities. During the concept design phase, the team uses cardboard models and simulations to quickly validate the assembly process, identify potential issues early, and optimize the design. After the activity, the team obtains a validated production readiness plan, including draft standard work and vertical take-off milestones, so mass production hits target from day one with no ramp-up period.