Team5A-ALUETEMaterialReplenishmentImprovement(精益生.ppt

KaizenTemplates SupplyChain GBE KPO 4 002 00Revision13 ProjectTitle ALUETEMaterialReplenishmentImprovementSite FlextronicsNanjingLine Area 3FSupermarketTeam Team5ADate 2011 3 7to2011 3 18Category SupplyChainType ExternalKaizen 2 ThisdocumentisproprietaryandconfidentialpropertyofFlextronics TableofContents PDCA Plan Do Check Adjust 4IndependentStudyonKaizenNeeds5KaizenTeamMembers6Goals Objectives7TargetSheet8ValueStreamMap9StandardWorkSheet Before 11 13SpaghettiChart Before 14Before AfterKaizen15 20 ContentsSlide s ContentsSlide s SpaghettiChart After 21StandardWorkSheet After 22 23KaizenNewsPaper24 26KaizenLog HomeworkMovingForward 27Lesson ToolsLearned28KaizenLog ProposalforYokoten 29AttendanceList30 31FinancialPerformanceDashboard32VSMIcon Symbols33VSMDottingProcess Keynotes34 4 1 Adjust 4 Check 2 Plan LeaninOperations PDCATitle ALUETEMaterialReplenishmentImprovement ALUETEofallissuedowntimeaverageat714mins day duetomaterialsupplyDownTimeaverageat80minute day 3 Do 5 IndependentStudyonKaizenNeeds PresentSituationandProblems Inthepast8weeks SMTandbackendlinewaitingmaterialtimetotalat641minuets Dailydowntimeaverageat80minutes Oursupermarketnotmatchthemeetsupermarketchecklist 1 Valuestreammappingtodefinethevalueandfindouttheimprovementpoint 2 Setupsupermarketandloadmaterialreplenishmentsystem 3 Standardizewaterstriderworktomaketheallstepsstandardandclearly 1 No ofitemsinsupermarketimprovefrom375to637 allofparts 2 SMTmaterialkittingtimereducefrom12hoursto4hoursAssemblymaterialkittingtimereducefrom8hoursto2hours3 Materialpickuptimefrom20sto3s4 Meetsupermarketitemsfrom2to15 6 KaizenTeamMembers 7 Note PlsensurethatallG Oidentifiedinthispageiscapturedunderthetargetsheet Goals Objectives Objectives1 ALUETEmaterialsupplydowntimeas0 Goals 8 TargetSheet Notes UsethisTargetSheetifprojectisnottrackingETEPleaseensurealltheG O sidentifiedinPage5iscaptured Siteleanleaderisresponsibleinreviewingthisandensuringthatafollowthruisdonetilltheclosure 9 CurrentValueStreamMapping TopLevel 10 StandardWorkSheet Before 11 StandardWorkSheet Before 12 StandardWorkSheet Before 13 StandardWorkSheet Before SpaghettiChart Before Productionlinekittingway Warehousekittingway Productionline LeaninSupplyChainTitle SupermarketPickUpViewControl BeforeKaizen AfterKaizen Theoldsupermarketnoclearvisualmanagement Addthelocationmark waterstridercaneasytofindmaterial Source ShingijutsuSiteName NanjingMonth Year Mar 2011Jake wu BeforeKaizen AfterKaizen Source ShingijutsuSiteName NanjingMonth Year Mar 2011Link Sun LeaninSupplyChainTitle VisualManagementImprovementforSupermarket Nogoodvisualmanagement noclearruleformaterialreplenishment Improvevisualmanagement definethematerialreplenishmentrule 17 BeforeKaizen AfterKaizen Source ShingijutsuSiteName NanjingMonth Year Mar 2011Jake wu LeaninSupplyChainTitle SupermarketFIFOImprovement NoFIFOcontrol ClearFIFOcontrol 18 BeforeKaizen AfterKaizen Source ShingijutsuSiteName NanjingMonth Year March2011Link Sun LeaninSupplyChainTitle MaterialReplenishmentTimeReduction Theoldprocessneedmorethan12hourstopreparematerial Nowjustneed1hourtopreparethematerial 19 BeforeKaizen AfterKaizen Source ShingijutsuSiteName NanjingMonth Year March2011Link Sun LeaninSupplyChainTitle KaizenForSupermarketPickupViewControl Thekittingcarisveryheavyandbig noteasytoused Thenewcarcanmatch1hourkitting1time andaddthedeskandkanbancardcollectbox itveryeasyusedforwaterspider BeforeKaizen AfterKaizen Source ShingijutsuSiteName NanjingMonth Year March2011Link Sun PC keyboard scanner LeaninSupplyChainTitle KaizenForSupermarketPickupViewControl Transferwayis252M bookingtimeis1800Sec Transferwayis115 2M bookingtimeis20Sec SpaghettiChart After Productionline Productionlinekittingway Warehousekittingway WarehousekittingTransfer reducefrom180Mto72M ProductionlinekittingTransfer reducefrom72Mto43 2M StandardWorkSheet After 23 StandardWorkSheet After KaizenNewsPaper NoMoneyNoPeopleNoSpace 25 KaizenNewsPaper NoMoneyNoPeopleNoSpace 26 KaizenNewsPaper NoMoneyNoPeopleNoSpace Note Pleaseincludefollowupactionitemsthatneedstobecontinuedaftertheworkshop Thefollowthrutargetswillneedtobeincludedinthelongtermtargetsheetinthenextslide Siteleanleaderisresponsibleinfollowingthrutheactionsidentifiedinthekaizenlog KaizenLog HomeworkMovingForward Lessons ToolsLearned Note Pleaseincludefollowupactionitemsthatneedstobecontinuedaftertheworkshop Siteleanleaderisresponsibleinfollowingthrutheactionsidentifiedinthekaizenlog Siteleanleaderwillselecttheitemsidentifiedhereforyokotenandwillbetransferredtotheyokotentracking KaizenLog ProposalforYokoten 30 KaizenWorkshopAttendanceList AM SessionBeforeLunchPM AfterLunchSessionPM1 EveningSession AfterLeadersMeeting Note Teammember ssignature KaizenWorkshopAttendanceList AM SessionBeforeLunchPM AfterLunchSessionPM1 EveningSession AfterLeadersMeeting Note Teammember ssignature KaizenProjectSummary Team5AFinancialPerformanceDashboard Note TobecompletedandpresentedonFridayAllfinancialstobevalidatedbysiteFinanceController ValueStreamMapping Icon Symbol ManualTransport PersonalComputer Customer Document MultiDocumentation Decision ExternalScheduleorEvent TechnologyUsed Supplier Forklift Store Supermarket Inventory Receipts PickingCart Truck DataBox W T P T Quality Withdrawal Pull InBox Queue IN MovementbyPush Iterations ABCD LevelingMix orVolume Tel Telecom Changeover KaizenLightningBurst WeeklySchedule FIFO FirstInFirstOut KanbanPost ShipmentIn Out ElectronicInfo Ele