《劳斯莱斯精益案例》PPT课件.ppt

ValueStreamMapping ValueSteamMapping TheValueStream adefinition Allofthestepsrequiredtobringaproductorservicefromrawstatethroughtothecustomer TotalValueStream Supplier ProcessC ProcessB ProcessA Customer InternalPlant 2 ValueSteamMapping WhatisValueStreamMapping ValueStreamMappingisapowerfultechniquethatallowsustocreatea BIGPICTURE visualrepresentationof Allthestepsintheprocess workingbackfromcustomerdemandtorawmaterial Theflowofbothmaterialandinformationandtheeffecttheyhaveoneachother Thedistinctionbetweenvalue addedandnon value addedactivity WASTE Theeffectalloftheabovehaveonmeetingthecustomer srequirements 3 ValueSteamMapping The8Wastes Scrap Rework Over production Inventory Motion Processing Transportation Under utilizedPeopleWaiting manpower material machine 4 ValueSteamMapping 1Scrap Rework Definition Anyproductthatdoesnotmeetspecificationsandthereforeeitherneedstobereworkedorscrapped Goal 100 FirstTimeThroughQuality 5 ValueSteamMapping 2Over production Under Definition Producingmorethanisnecessary oftencausingWIP WorkInProcess workingonpartsaheadofschedulewhiledelinquentpartswait Goal ProducetoTargetCycleTimetheneventuallyproducealloperationstoTaktTimeintheFutureState 6 ValueSteamMapping 3Inventory Definition materialorpartsthatarestoredforfutureuseorshipment Before After Ifyouhadonly30secondstofindtheunit whichstoragesystemwouldyouchoose 7 ValueSteamMapping 4Motion Definition Excessivemotionbeyondwhatisneededtogetthejobdone Goal SameasDefinition sitting searching turningaround walking climbing choosing bendinglyingdownover 8 ValueSteamMapping 5Processing Over Under Definition Extraand orunnecessaryoperations Standardizationofoperationsnotthoroughenough Processingapartabovespecifications Goal Processpartsthatconsistentlymeettheminimumcustomerrequirements100 ofthetime 9 ValueSteamMapping 6Transportation Definition Movingpartstounnecessarydistancesfromoneoperationtoanother Goal Putoperationsinorder minimizeoreliminatethetraveldistancebetweenthem 10 ValueSteamMapping 7Waiting Definition apersonorpart s sittingidlewhilewaitingformaterial asupervisor thenextoperation etc Goal Eliminatetheunplannedinterruptionsthatoccurduetoinefficiencies Developcontinuousflowwhereverpossible Convertwaitingtovalue addedwork 11 ValueSteamMapping 8Under utilizedPeople Definition Skillsuntapped Ideasnotimplementedandimprovementsnotrealized Goal Tapintotheenergiesandunusedimprovementideasfromtheworkforce 12 ValueSteamMapping ExerciseWorksheet MANUFACTURINGWASTESIDENTIFICATIONSHEET Dept Transportation Under utilizedPeople Scrap Rework Over Under Production Processing 5S Sort Straighten Sweep Standardize SelfDiscipline Inventory NO WASTEIDENTIFIED JohnMcLauchlin RevisionDate 4 25 2000 Waiting Motion 13 ValueSteamMapping ValueStreamAnalysisProcess ValueStreamMapping 1 0SelectChampionandInitialProductFamily 2 0Gather Map andAnalyzeSelectedValueStreamData 3 0DesignFutureState 4 0ImplementationPlanningandExecution 1 Understandbusinessgoalsandcustomerobjectives 2 Selectchampionandvaluestreamleadersbasedonprovencriteriaforsuccess 3 Defineproductfamiliesbasedoncommonprocessesandequipment 14 ValueSteamMapping LeadershipandChampions Observations LeanAerospaceInitiative AcommonfactorinallobservedsuccessfulleanimplementationsisoneormoreempoweredChampions Championsareusuallyhigh levelleaderswhotakeonapro activeroleshapingandsupportingtheleaninitiatives andensuringthatsystembarriersareidentifiedandaddressed Tostartyourleanjourney youneedaleaderorsetofleadersto Developastrategicdirection Agreetoandcommunicatethestrategicdirection Makeavailabletheneededresources Providecontinued visiblesupport Withoutthesupportofachampion youshouldnotattempttoimplementleanpracticesandprinciples itisarecipefordisaster 15 ValueSteamMapping SmallGroupActivity Identifywhoinyourorganizationwillfillthesecriticalrolestosupportleanimplementation ExecutiveChampion ImplementationLeader OperationsManager TechnicalSupport OtherKeyRoles Brieflydescribetheroleeachpersonwillhaveinsupportinglean Whatcanyoudotogetthesepeopletosuccessfullysupportyourefforts ExecutiveChampion ImplementationLeader OperationalMgr 16 ValueSteamMapping DefineProductFamilies AnalyzeProduct VolumeCharttoseparatehighrunnersfromlowrunners AnalyzeProduct ProcessMatrixtoidentifysimilarprocessingstepsandcommonequipment AnalyzeRoutingstoidentifycommonsequencesfocusingon Operationsthatcanpotentiallybededicatedtotheproductfamily Operationsthatareneithermonumentsnorbatchcycles Downstreamprocessesmostvisibletothecustomer 17 ValueSteamMapping AnalyzeProduct VolumeCharttoseparatehighrunnersfromlowrunners ProductVolumeChart 4500 4000 3500 AnnualVolume 3000 2500 2000 1500 1000 500 0 2206 2150 2170 2158 2108 2142 2124 2102 2172 2212 2222 2202 2204 PartNumber 18 ValueSteamMapping AnalyzeProduct processMatrixtoIdentifySimilarProcessingStepsandCommonEquipment Vol 400 360 450 450 760 620 750 322 58 300 268 4000 PNs 2124 2102 2108 2142 2150 2158 2170 2172 2204 2212 2222 2206 4070 Rough H T Turn Deburr Insp Black MPI Ship Mark Mill Saw Drill Coppr Grind Weld Plasma X X X X X X X X X X X X X X X X X X X X 8338 X X X X X X X X X X X 8338 X X X X X X X X X X X 8338 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X 3978 3138 1800 5200 0 X X X X X X X X 8280 3712 X X X X X X X 4326 X 4000 58 4280 8338 19 ValueSteamMapping AnalyzeRoutingstoIdentifyCommonSequences TypesofMachines Rough 1 2 3 4 4 5 6 Insp Black MPI Grind Weld Coppr Plasma 7 8 9 10 11 12 14 ASSM FPI Coat Lap Polish Paint Nickel 15 16 17 18 19 20 21 BatchorOutSourced Non monument H T Turn Mill Drill Deburr Mark ProductFamily A 2124 2102 2108 2142 2150 2158 2172 2170 2204 2212 2222 2206 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 2 2 1 1 1 2 2 2 1 2 1 12 2 7 2 3 2 3 3 3 3 3 3 3 3 3 3 3 3 4 5 3 3 3 3 3 3 3 3 3 3 3 3 3 4 4 4 4 4 4 4 4 4 10 4 4 5 5 5 5 5 5 5 5 5 11 5 5 6 6 6 6 6 6 6 6 6 15 8 8 8 8 8 8 8 8 14 9 9 11 9 9 9 7 7 7 7 7 7 3 3 3 9 9 10 21 17 3 7 7 7 5 5 10 4 16 16 3 19 3 15 7 15 7 20 7 15 7 1 1 2 2 2 3 3 3 3 3 3 C B 50 ofTotalVolume 20 ValueSteamMapping ValueStreamAnalysisProcess ValueStreamMapping 1 0SelectChampionandInitialProductFamily 2 0Gather Map andAnalyzeSelectedValueStreamData 3 0DesignFutureState 4 0ImplementationPlanningandExecution 1 Gathercustomerinformation 2 Walktheprocess sketchprocessboxes 3 Fillinprocessdataboxesandinventorylevels byproduct 4 Documenthowgoodsaredeliveredtothecustomer 5 Gatherinformationonsuppliers 6 Addinformationflows 7 Sketchhowmaterialmovesbetweenprocesses 8 Drawproductionleadtime value addedtimeline 21 ValueSteamMapping MaterialFlowIcons Assembly XYZCorporation ProcessBox Supplier Customer C T 45sec C O 30min 3Shifts 2 Scrap I 300pieces1day Inventory Supermarket BufferorSafetyStock DataBox Mon Wed Shipment Push PhysicalPull FinishedGoodstoCustomer FIFO First In First Out Operator 22 ValueSteamMapping InformationFlowIcons WeeklySchedule ManualInformationFlow ElectronicInformationFlow Schedule OXOX LoadLevelingBox Sequenced PullBall Uptime Changeover WithdrawalKanban ProductionKanban SignalKanban KanbanPost KaizenLightningBurst 23 ValueSteamMapping MappingTips Useapencilanddrawon11 x17 paperorlarger Drawtopofprocessboxesjustbelowthemiddleofthepage Leaveenoughroombetweenprocessboxestoshowinventory Decidewhethertocountallpartsorjustasamplepart Drawonlyonetothreemainsuppliers supplieditems Productionleadtimeiscalculatedbydividinginventoryquantitybydailycustomerrequirement PutaTitleanddateonmapandincludeCustomerRequirements Makeeveryefforttocollectgooddata Usealternatemethodsforcollectingdatawhentimeisaconstraint Compareagainstrecenthistoricaldataasasanitycheck 24 CurrentStateValueStreamMap Supplier Customer Customerrequirement500bladesperweek 2 1 1 11 22 21 CurrentStateValueStreamMap Supplier Customer Customerrequirement500bladesperweek Daily Daily I 2 I 1 I 1 I 11 I 22 I 21 I 600 108 156 208 174 72 184 CurrentStateValueStreamMap 2yearForecast Supplier 90dayorder Weeklyorder 90Dayproductionplan 2yearForecast MRPFunction 90dayorder Weeklyorder Customer Daily WeeklySchedule DailyMeeting Daily Customerrequirement500bladesperweek Daily Daily I 2 I 1 I 1 I 11 I 22 I 21 I 600 108 156 208 174 72 184 CurrentStateValueStreamMap 2yearForecast Supplier 90dayorder Weeklyorder 90Dayproductionplan 2yearForecast MRPFunction 90dayorder Weeklyorder Customer Daily WeeklySchedule DailyMeeting Daily Customerrequirement500bladesperweek Daily Daily I 2 I 1 I 1 I 11 I 22 I 21 I 600 108 156 208 174 72 184 VARatio 0 8 Exercise ABCForging Sampledata CustomerDemand ProductMix VolumeA VolumeB VolumeC VolumeD VolumeE 5Discs 500 yr 500 yr 500 yr 150 yr 100 yr Delivery Scorecard Quality Concessions 0ppm 15 000cppm dimensional 75 ResponseTime 70days Transportation DistancetoCustomer 200mi DistanceHT Insp 150mi ResponseTime 5day ProductionProcess Op Saw HT C T 15m 9h 4h C O 20m 1 5h Inv 35 119 14 98 49 21 Misc 20 time 2h Heat 8h Cool 5 rework Scheduling Two8 hrshifts 30minbreakpershift 5workdays week 50weeks year Customerprovides2 yearforecast 60 dayflexibleschedule weeklypullsignal Aeroprovidessub tiersw 2yrforecastand8 weekfirmschedule AerousingMRPtoscheduleeachworkcenter supervisorsexpeditedaily Batchsizeof40piecesthroughprocess averageleadtimeof 10weeks Forge 07m Insp 03m Mach 3h Insp 1 5h Pack 5m OutsourcedOperations ValueSteamMapping ProcessInformationSheet Supplier PartName TimefromTimeelaspsedfinishinglastAvailableorfromfinishingonegoodpartofoneassignednumberparttofinishingproductionruntoofminutesforthenextpart withfirstgoodpartofeachoperationinaDescriptionoftheprocessbeingperformednosetup nextrun24hourperiod PartNo Ave numberofpartsrunbeforemovingallpartstonextoperation AnnualVolume RoutingOperationNumber Vendorname outsourcedoperationsonly Cityandstatewhereoutsourcedoperationisperformed Traveldistancetooutsidevendors Meansofconveyence Averagetimeapartspendsateachoperation Operation Description CycleTimeChange min Over min AvailableMinutesperDay BatchSize Vendor Location DistancefromPlantMethodof miles Transport LeadTime days 30 ValueSteamMapping ValueStreamAnalysisProcess ValueStreamMapping 1 0SelectChampionand