公司价值流程图的制作规范.ppt

ValueStreamMap,WCLEOfficeTrainingMaterial,Page2,ValueStreamMapping(VSM),WhatisaValueStream?,Page3,ValueStreamisalltheActivities(bothVAandNVA)requiredtobringaproductthroughfromrawmaterialstothehandsoftheCustomerValueStreamMapisastandardMethodforhighlevelprocessMapping,Molding,Trim,Assembly,WhatisaValueStream?,Page4,Helpstovisualize/understand/highlightMaterial&InformationFlowHelpstoseeWasteandImproveopportunitiesAllowseveryonetogainacommonunderstandingoftheCurrentstate(AS-IS)andtheFuturevision(TO-BE),WhatsinItforMe?,Page5,StepsforValueStreamMapping,4,CurrentVSM,FutureVSM,Planandfollowup,WHEREWeAREWHERETOGOHOWTOGO,Level1ValueStreamMapping-VSM(Strategicdirection),Level2Functionalmapping(Processre-engineering),Level3Flowdiagramformaterialsandinformation(Improvementofworkmethods),Level1ValueStreamMapping,Leanmakessense精益能够做到,Processviewedbyyou你所见到的流程,Processinreality实际执行的流程,Targetedprocess精益流程,Software?,SMART!,Page8,CURRENTLCMFLOW,Normalflowfromcustomertocustomer,LeadtimebetweenOIanddeliveryreadytobeshipped:from8to4weeksOTIF:85%ofeverylineshipped,Page9,Selectproduct/processfamily,Drawcurrentstate,Createfuturestate,Implementactionplan,StepsforValueStreamMapping,RepeattheProcess,Selectpriorityprocesses,IdentifywastesandimprovementopportunitiesDrawideasdirectlyonVSM,Drawprocessusingpencil/eraserCollectallpossibledataonshopfloor,TIPS,STEPS,Develop&executeakaizenplanReviewplanregularlytoachievefuturestate,Continuousimprovement,Page10,Selectproduct/processfamily,Drawcurrentstate,Createfuturestate,Develop/executeimprove,StepsforValueStreamMapping,RepeattheProcess,Page11,#1SelectProductFamilyPQPRexample,PROCESSMACHINES,Tocreateaproductfamilymatrix,listyourproductsandtheprocessstepsworkingbackwardsfromthecustomeralongthetop.LookforcommonprocessstepsthatapplytoseveralproductsTheseproductscanthenbegroupedintofamilies.,Page12,Selectproduct/processfamily,Drawcurrentstate,Createfuturestate,Implementactionplan,StepsforValueStreamMapping,RepeattheProcess,Page13,#2DrawCurrentState,Somehints:Useactual,observeddataBeginatendpoint&proceedinreverseflowWalktheentireprocessfirstbeforerecordingdataEveryoneontheteamshouldcreatetheirownmapUsepencilandpaper,Page14,#2DrawCurrentState:SampleSymbols,Machining,ProcessBox,DataBox,I,Inventory,1,Operator,ManualInformation,ElectronicInformation,InspectionPoint,WithdrawalKanban,PushArrow,Customers/Suppliers,ToCustomer,ProductionKanban,Supermarket,TruckShipment,FutureStateImprovement,“GoSee”Scheduling,DailySchedule,Schedule,Page15,MANUFACTURINGCycleTime(machine,manual)LeadTimeQueueTimeTransportationTimeChangeOvertime(c/o)Availability(uptime)Batch(lot)SizeQuality%(scraprate,reworks,.)n#Operators,PROCUREMENTLTfromPartRequesttoPurchaseOrdern#ofPR/POtobeprocessed(queue)Quality%=POprocessedwithouterrorsn#resourcedused,DESIGNLTtoBOManddwgemissionn#oforderstobeprocessed(queue)Quality%ofcorrectBOM/dwg1timeDelivery%ofBOManddrawingontimevs.totaln#resourcedusedper#ofshiftsn#drawingchanges,#2CurrentStateExampleofdatatocollect,Notsonecessarytobesoprecise,butgoodreferenceforjudgment!,Page16,CustomerorSupplierProcess(endswhentheflowstops),Usethefollowingforms:,#2CurrentStatePROCESS&ACTIVITYINVOLVED,Page17,Inventory,WIPFlowofmaterial(productionpushflow)FlowoffinishedgoodsorrawmaterialsMeansoftransportation,Usethefollowingforms:,#2CurrentStateMATERIALFLOW,Page18,wklyorder,#2CURRENTSTATEInformationflow,Page19,#2CURRENTSTATEDatabox,Page20,Machine,x2,C/T54sec,C/O34min,2shifts,UT90%,#2CURRENTSTATEDatabox,Page21,#2CURRENTSTATETimelineofProductionleadtime,Page22,#2CURRENTSTATEExamples,Byhand,Page23,Selectproduct/processfamily,Drawcurrentstate,Createfuturestate,Implementactionplan,StepsforValueStreamMapping,RepeattheProcess,Page24,IsthebasisofaplantowardsaLeanProductionSystemAllowsfullparticipationandbuy-inoftheteamindevelopingthefuturevisionofthebusinessSummarizeimprovementneedsIsastreamofvalue-addingflowlinkedtothecustomerbypullorcontinuousflow,#3FUTURESTATEPurpose,Page25,Doesthestepbringvaluetothecustomer?ifnot,andifpossibletrytoeliminatestep,#3FUTURESTATEHintstodrawthevision,Isthestepcapable(sameresulteverytime)?ifnot,looktheQualityprocess,reducevariance,Areprocessstepslinkedbypull,doestheproductflowtothenext?ifnotimplementJustInTime(fromBatchtoFlow,U-cell,Takt-time,Stdwork),WhereyoucannotFlow(combinede-coupledprocess)gofromPushtoPulltoreduceinventoryusingkanban,supermarket,Batch,Page26,Isthestepavailable:canitproducethedesiredoutput&quality,everytime?ifnot,implementTotalProductiveMaintenance,#3FUTURESTATEHintstodrawthevision,Isthestepadequate:isthecapacitytolow(productiswaitingforthestep)ortohigh(bigmachines)reducecycle,increasecapacity,reviewbottleneckexploitationandworkrelease,Isthestepflexible:canitbechangedoverquicklytoallowsmalllot/singlepieceproduction?ifnot,implementSingleMinuteExchangeofDies(SMED),Page27,X,X,X,X,#3FUTURESTATEHighlightimproveopportunities,Page28,#3FUTURESTATEPlotthevision,U-cell,Kanban&Smkt,SMED,Flow,ProductLeveling,Fifoline,StdWork,Page29,Selectproduct/processfamily,Drawcurrentstate,Createfuturestate,Implementactionplan,StepsforValueStreamMapping,RepeattheProcess,Page30,KaizenPlan&Newspaper,Plan,Execute,VerifyandControlimprovementsteps,Page31,Selectproduct/processfamily,Drawcurrentstate,Createfuturestate,Develop/executeimprove,StepsforValueStreamMapping,RepeattheProcess,Page32,WhentheFutureStatebecomesareality,itbecomesourcurrentstateWeareonlyatthebeginningofourcontinuousimprovementjourneyStriveforPERFECTION!,Isito