105 价值流分析.pdf

105 价值流分析 精益管理系列课程 Heijunka Averaged daily volume & mix Smooth production scheduleStandard Work Kaizen Jidoka Built-in quality Pokayoke 5 Why Harmony of man & machine Creative Idea Suggestion System 5S 3PTPMSMED Visual Contro ls Kanban Operational Excellence Best Cost, Quality, Delivery Empowered employees Customer focused culture TPS Just In Time Takt Time One-piece Flow Downstream Pull 价值流分析内容安排 ?什么是价值流? ?什么是价值流图 (VSM)? ?为什么采用价值流分析? ?价值流分析逐步展开 什么是价值流 ?完成顾客要求所需的步骤或活动 ?其中包括增值和不增值 ?显示作业流动 (物料和信息) ?实例: ?“定单到现金” ?“概念到发布” ?“定单到发运” 价值流图的来源 MIF = 物料和信息流程图 由丰田公司开发用于分析和 改进流程的工具 价值流分析可用于任何生产或服务活动。 要求 交付 需求 供应 集团级 公司级 = 流程 部门级 绘制层次 目视 ?整体流程目视化，而不仅仅是单个流程 ?从顾客角度看待流程（外部顾客） ?上游对下游工序的影响 (内部顾客) ?便于识别流程中浪费 ?显示物料和信息流之间的联系 ?将不同部门或职能的问题联系在一起 为什么采用价值流图 改变 ?提供改进活动实施的蓝图 ?易于实际作业员工参与 ?激发员工从不同角度看问题 ?提供流程观察的共同语言 ?将所有信息显示在一起 为什么采用价值流图 聚焦 ?关注流程 (而非产品) ?关注系统 (而非局部优化) ?改进活动与业务目标相联系 ?改进正确的区域 为什么采用价值流图 价值流分析活动的输出 ?现状图: 显示现时物流和信息流 ?识别浪费和系统问题 ?未来图: 显示目标物流和信息流 ?减少浪费，实施精益系统 ?实施工作计划达到未来状态 ?设定变革计划优先权 Assembly 45,000pcs/mo - 5,400 P -3,940 NP Tray = 20 pcs 2 shifts 1x Daily OCT 2 shifts C/O %UP Productivity VA Space/ratio BeforeAfter Product travel 120 seconds 0 min 90% 5 boxes/person/hr 0ft2/(1/50) 150ft 600 P pcs 155 NP pcs 5,400P pcs 3,940 pcs Information flowProduct flowManualPush + SHIPPINGSHIPPING 5 27,600 sec/shift + I 2700P 1440NP I950P 500NP I355 OCT 2 shifts C/O %UP FPY or RTY VA Time Productivity VA Space/ratio Before After Product travel 200 seconds 0 min 90% 95% or 72.9% 12.5 pcs/person/hr 6ft2/(1/20) 25 sec 256ft 355 pcs 400P pcs 500NP pcs Information flowProduct flowManualPush + ASSEMBLY #2 1 27,600 sec/shift OCT 2 shifts C/O %UP FPY or RTY VA Time Cell Productivity VA Space/ratio Before After Product travel 40 seconds 0 min 90% 95% or 72.9% 10 pcs/person/hr 2ft2/(1/100) 35 sec 30ft 125pcs 0 pcs Information flowProduct flowManualPush GRINDGRIND 1 27,600 sec/shift Auto55 seconds 375I OCT Auto C/O %UP FPY or RTY VA Time Productivity VA Space/ratio BeforeAfter Product travel 30 seconds 30 min 90% 85% or 59% 150 pumps/person/hr 2ft2/(1/300) 5 sec 660ft 550pcs 2,100P pcs 1,285NP pcs Information flowProduct flowManualPush PAINTPAINT 2 60 sec/shift EPE3 days OCT 3 shifts C/O %UP FPY or RTY VA Time Cell Productivity VA Space/ratio Before After Product travel 160 seconds 60 min 90% 98% or 74% 10 pcs/person/hr 0.5ft2/(1/500) 15,000 sec 1200ft 190pcs 250pcs Information flowProduct flowManualPush HEAT TREATHEAT TREAT 3 40,000 sec/shift Auto54,000 seconds I340 OCT 3 shifts C/O %UP FPY or RTY VA Time VA Space BeforeAfter Product travel 55 seconds 90 min 90% 95% or 72.9% 2ft2 35 sec 25ft 125pcs 150pcs Information flowProduct flowManualPush TURN #2TURN #2 1 40,000 sec/shift Auto45 seconds VA Space/ratio2/(1/100) 275I OCT 3 shifts C/O %UP FPY or RTY VA Time VA Space BeforeAfter Product travel 45 seconds 90 min 90% 95% or 72.9% 2.25ft2 45 sec 25ft 225pcs 150pcs Information flowProduct flowManualPush MILLMILL 1 40,000 sec/shift Auto55 seconds VA Space/ratio2.25/(1/200) I OCT 2 shifts C/O %UP FPY or RTY VA Time VA Space BeforeAfter Product travel 45 seconds 0 min 90% 95% or 72.9% 2.5ft2 45 sec 500ft 125pcs 150pcs Information flowProduct flowManualPush TURN #1TURN #1 1 27,600 sec/shift Auto55 seconds VA Space/ratio2.5/(1/100) 375 0.4D 21D 0.2D0.3D0.4D0.3D 1.5D4.1D 100S100S100S 54.1K Sec 95Sec 200 Sec 90 Sec 120 Sec 45 S 45 S 35S 15K Sec 35 Sec 25 Sec 5 Sec 500 25 traveltravel VA SpaceVA Space (ratio)(ratio) 25120030256 660150450 2.5 (1/100) 2.25 (1/200) 2.0 (1/100) 2.5 (1/500) 2.0 (1/100) 2.0 (1/20) 2.0 (1/300) 0.0 (1/50) Tues. + Thurs Gemba Forging Co. 2000 pcs 3266 15.25 16.9K Sec 28.8 Days PRODUCTION CONTROL MRP Daily Order 30/60/90 day Forecasts Weekly Release 6-week Forecasts FORGING RMFORGING RM 现状图 ?现状图代表观察现有价值流的实际状态。 ?从顾客开始 (需求) ?定义数据表 (流程) ?画出材料流 (推动，拉动) ?画出信息流 (触发) 现状图绘制的十大步骤 1.选择价值流 ?识别主要价值流 ?分析产品族 ?分析顾客需求 2.绘制整体作业流动 3.识别关键指标 4.完成数据表 5.绘制等待天数 6.填充时间线 7.计算增值比例 8.绘制原材料供应 9.绘制信息流 10.识别改善项目 OCT 2 shifts C/O %UP FPY or RTY VA Time Productivity VA Space/ratio BeforeAfter Product travel 110 seconds 0 min 95% 98% or 76% 40 pcs/person/hr 4ft2/(1/20) 25 sec 25ft 5pcs 5pcs Information flowProduct flowManualPull + ASSEMBLE & PAINT & PackASSEMBLE & PAINT & Pack 2 27,600 sec/shift OCT 2 shifts C/O %UP FPY or RTY VA Time Productivity VA Space/ratio Before After Product travel 90 seconds 20 min 98% 98% or 78% 25 pcs/person/hr 2ft2/(1/20) 135sec 20ft 4pcs 5pcs Information flowProduct flowMPull Rotor CellRotor Cell 2 27,600 sec/shift Auto 220 seconds OCT 2 shifts C/O %UP FPY or RTY VA Time Productivity VA Space/ratio Before After Product travel 120 seconds 20 min 95% 98% or 78% 25 pcs/person/hr 8ft2/(1/20) 185sec 20ft 15pcs 5pcs Information flowProduct flowMPull Housing CellHousing Cell 1 27,600 sec/shift Auto 200 seconds OCT 2 shifts C/O %UP FPY or RTY VA Time Productivity VA Space/ratio BeforeAfter Product travel 89 seconds 20 min 95% 98% or 78% 25 pcs/person/hr 8ft2/(1/20) 185sec 20ft 5pcs5pcs Information flowProduct flowMPull Manifold CellManifold Cell 2 27,600 sec/shift Auto 200 seconds OCT 2 shifts C/O %UP FPY or RTY VA Time Productivity VA Space/ratio Before After Product travel 90 seconds 20 min 98% 98% or 78% 25 pcs/person/hr 2ft2/(1/20) 135sec 20ft 4pcs 5pcs Information flowProduct flowMPull Rotor CellRotor Cell 2 27,600 sec/shift Auto 220 seconds FORGING RMFORGING RM Assembly 45,000pcs/ mo - 5,400 P -3,940 NP Tray = 20 pcs 2 shifts 1x Daily daily Gemba Forging Co. 2000 pcs PRODUCTI ON CONTROLMRP Daily Order 30/60/90 day Forecasts Weekly Release 6-week Forecasts 未来状态图 未来状态图代表在未来的6个月将要达到的理想状态。 设定改进目标 20,000 PPM $187,000 / 人 2,225 m2 3 天 $230,000 $130,000 $340,000 未来 56%45,000 PPM缺陷 34%$139,000 / 人生产率 55%5,000 m2场地 83%17 天交货期 58%$545,000成品 72%$450,000在制品 32%$500,000原材料 %现状指标 价值流实施计划 ?简单最佳! 使用一页计划文件来识别做什么，谁来做， 时间和结果。价值流计划可以使用以下几种格式: ?X-矩阵 ?甘特图 ?保龄球图 ?A3 报告 1st Level Policy Deployment X Reduce signal to material receiptX 12 X Reduce material receipt to assembly complete lead timeX2122 XX Direct material costX1 XXAcq rate effectivenessX1 Reduce time to market by 2 months Reduce cost by 7% Supplier lead-times to 10.5 mo