精益生产_精益生产价值流图

ENERGIZERSCHICK HIGHLYCONFIDENTIAL RESTRICTEDFORINTERNALUSEONLY 1 LeanManufacturingValueStreamMapping ENERGIZERSCHICK HIGHLYCONFIDENTIAL RESTRICTEDFORINTERNALUSEONLY 2 WhatisLean Leanisathatfocuseson CreatingvaluefortheCustomerEliminatingWasteContinuousincrementalimprovement ThinkingProcess ENERGIZERSCHICK HIGHLYCONFIDENTIAL RESTRICTEDFORINTERNALUSEONLY 3 WhatisaValueStream Alloftheactions valueornonvalueaddedthatarerequiredtobringaproductfromconcepttolaunchorfromrawmaterialordertodelivery From LeanLexicon ENERGIZERSCHICK HIGHLYCONFIDENTIAL RESTRICTEDFORINTERNALUSEONLY 4 OrderFulfillmentValueStream Ideally we dwantthematerials informationandcashtoflowsmoothly withoutinterruption andasquicklyaspossiblethroughthisstream ENERGIZERSCHICK HIGHLYCONFIDENTIAL RESTRICTEDFORINTERNALUSEONLY 5 LeanElements ValueStream ValueProvidingProcesses Pull Perfection Flow Value ENERGIZERSCHICK HIGHLYCONFIDENTIAL RESTRICTEDFORINTERNALUSEONLY 6 Value WhatisthewillingtoPayfor 3TypesofCustomers Theexternalend userorpayingcustomerThedownstreamcustomerofanyinternalupstreamprocess Yourcompanyasthecustomerofexternalsuppliers Customer ENERGIZERSCHICK HIGHLYCONFIDENTIAL RESTRICTEDFORINTERNALUSEONLY 7 Flow Idealflow 1pieceatatimeRatedeterminedbycustomerdemand TakttimeWorkbalancedforeachpersonormachineTraveldistanceformaterials peopleminimizedStandardWorkutilizedFlowwhatyoucan Pullwhatyoucan t Requiresthatallstepsintheprocessbe Capable RighteverytimeAvailable AlwaysabletorunAdequate Capacitytoavoidbottlenecks ENERGIZERSCHICK HIGHLYCONFIDENTIAL RESTRICTEDFORINTERNALUSEONLY 8 PhasesofLeanJourney Phase1 Identify MapValueStreamsPhase2 PrioritizeopportunitiesPhase3 UtilizeLeantoolstoeliminatewastePhase4 ControltheflowPhase5 LeanmetricsPhase6 Re evaluateValueStreamsandbeginagain ENERGIZERSCHICK HIGHLYCONFIDENTIAL RESTRICTEDFORINTERNALUSEONLY 9 ItAllstartswithWasteIdentification IdentifyallformsofWastethroughoutourentireValueStreambefore ReducingthewasteorEliminatingthewasteThiswillenableustoprioritizeoureffortsandfocusonthehighpotentialeventsfirst ENERGIZERSCHICK HIGHLYCONFIDENTIAL RESTRICTEDFORINTERNALUSEONLY 10 8Wastes OverproductionInventoryWaitingTransportingUnnecessaryprocessingUnnecessarymotionDefectsUnderutilizationofpeople ENERGIZERSCHICK HIGHLYCONFIDENTIAL RESTRICTEDFORINTERNALUSEONLY 11 Over Production Producingmorethanwhatthecustomerreallywants WaystoOvercome ReducesetuptimesSynchronizetimeandamountofprocessesCreatecompactlayoutsandvisibility ENERGIZERSCHICK HIGHLYCONFIDENTIAL RESTRICTEDFORINTERNALUSEONLY 12 Inventory Excessinventoryrequireshandling space people andpaperwork WaystoOvercome SynchronizeworkflowtoreduceaccumulationShortensetuptimeReduceleadtimeCellularlayoutsZeroQualityDefectsReducingallotherwastesreducesthewasteofinventory ENERGIZERSCHICK HIGHLYCONFIDENTIAL RESTRICTEDFORINTERNALUSEONLY 13 Waiting Waitingforupstreamprocessesduetopoorlayout unbalancedworkloadorequipmentdowntime WaystoOvercome SynchronizeworkflowBalanceunevenloadsbyflexibleworkersandequipmentImplementpreventivemaintenancetoeliminatemachinedown time ENERGIZERSCHICK HIGHLYCONFIDENTIAL RESTRICTEDFORINTERNALUSEONLY 14 Transportation TransportationaddsNovaluetotheproduct Ratherthanimprovethetransportation ReduceitEliminateit WaystoOvercome Establishlayoutandlocationswhichreducesoreliminatestransportation ENERGIZERSCHICK HIGHLYCONFIDENTIAL RESTRICTEDFORINTERNALUSEONLY 15 UnnecessaryProcessing Samedataenteredinto3differentinformationsystems SAP Access Excel Allunnecessary orNon ValueAdded processingstepsshouldbeeliminated WaystoOvercome QuestionifprocessisnecessaryatallSimplifyUseStandardWorkReduceHandoffs approvals ENERGIZERSCHICK HIGHLYCONFIDENTIAL RESTRICTEDFORINTERNALUSEONLY 16 UnnecessaryMotion Motionofpeople machines andproductsiswaste WaystoOvercome Studymotionandeliminateorreducemotionthroughimprovedlayouts CellularManufacturingRethinkmaterialstorageJob TaskCombinations ENERGIZERSCHICK HIGHLYCONFIDENTIAL RESTRICTEDFORINTERNALUSEONLY 17 Defects Correction Makingdefectiveproductispure muda waste FocusonpreventingdefectsNotfindingandrepairingdefects WaystoOvercome Mistake prooftopreventdefectsNeverPassdefectsStandardWork ENERGIZERSCHICK HIGHLYCONFIDENTIAL RESTRICTEDFORINTERNALUSEONLY 18 WasteofUnderutilizingPeople Theeighthwasteisnotfullyutilizingthetimeandtalentsofpeople Whoarethe real experts andwhatdotheyknow ENERGIZERSCHICK HIGHLYCONFIDENTIAL RESTRICTEDFORINTERNALUSEONLY 19 PurposeofValueStreamMapping Thepurposeofthevaluestreammapistolookatthebigpictureandtodevelopa future state mapbyeliminatingallnon valueaddedactivitiesandminimizingallnon value addedbutrequiredactivities ENERGIZERSCHICK HIGHLYCONFIDENTIAL RESTRICTEDFORINTERNALUSEONLY 20 BasicCurrentStateMAPPINGTIPS 1Cross functionalTeamcompletesthemapStartatthecustomerendWalktheactualpathwaysofbothmaterialandinformationflow Drawbyhandinpencil ENERGIZERSCHICK HIGHLYCONFIDENTIAL RESTRICTEDFORINTERNALUSEONLY 21 ValueStreamMappingIconsProcessIcons ENERGIZERSCHICK HIGHLYCONFIDENTIAL RESTRICTEDFORINTERNALUSEONLY 22 ValueStreamMappingIconsInformationFlowIcons ENERGIZERSCHICK HIGHLYCONFIDENTIAL RESTRICTEDFORINTERNALUSEONLY 23 ENERGIZERSCHICK HIGHLYCONFIDENTIAL RESTRICTEDFORINTERNALUSEONLY 24 ProductionLeadTime 23 5daysValueAddedTime 184Seconds From LearningtoSee byMikeRotherandJohnShook CurrentStateMap ENERGIZERSCHICK HIGHLYCONFIDENTIAL RESTRICTEDFORINTERNALUSEONLY 25 FutureStateQuestions HowdowefocusontheLeadtime UnderstandthetakttimeWhatareaintheprocesstriggersproduction Willwebuildtoshippingortoasupermarket Wherecanweusecontinuousflow WhatitemsorEventsrequireProcessMapsHowdowesimplifyWheredowereducetravel redundancy Whatprocessimprovementscanwedo ENERGIZERSCHICK HIGHLYCONFIDENTIAL RESTRICTEDFORINTERNALUSEONLY 26 UsethelistoffuturestatequestionsHaveyourcross functionalgroupbrainstormUtilize outside folksandyourselftoquestioneverythingYoucansketchfuturestateideasatthetabletodiscussIfyouwishuseanoverheadasimpletransparenciesbyhandtoshowyourideasAfteryouhaveidentifiedalloftheimprovementsandopportunitieswhatwouldyourmaplooklikeYoumayreviseyourmapseveraltimesasyousimplifyMakesureyoucantraceallkeyproductandinformationflow LookfordisconnectsoroversightsinyournewmapbyfollowingitthroughasagroupexerciseWhatarethenewLeadandCycletimes Leadtimeisthekey TeamTips FutureStateMapping ENERGIZERSCHICK HIGHLYCONFIDENTIAL RESTRICTEDFORINTERNALUSEONLY 27 FromLearningtoSeebyMikeRotherandJohnShook FutureStateValueStreamMap ENERGIZERSCHICK HIGHLYCONFIDENTIAL RESTRICTEDFORINTERNALUSEONLY 28 BenefitsofValueStreamMapping Helpsyouvisualizemorethanthesingle processlevelClearlydefinesLeadandCycletimesHascross functionalaccuracyLinksthematerial informationflowsProvidesacommonlanguageandbasetoworkfromProvidesablueprintforimplementationMoreusefulthanquantitativetool