价值流分析培训.ppt

ValueStreamMapping,RecognizingtheValue-Addedstepsinyourprocesses,RecommendedReading,LearningtoSeebyMikeRotherandJohnShook,LevelsofValueStream,SupplyChaina.k.aValueStream,TotalValueStream,CustomertoConsumer,ValueStreamMapping,ValueStream-Allsteps,valueaddedandnonvalueadded,requiredtobringtheproductfromrawmaterialtocustomer.,WhatisaValueStreamMap?,AdetailedflowchartAbigpictureperspectiveimprovingthewhole,notjustoptimizingthepartsandmaybesub-optimizingthewholeWewillfocusonthedoor-to-doorproductioninsideaplantHelpsyouseeandunderstandtheflowofmaterialandinformation,ValueStreamMapping,BenefitsofValueStreamMapping,MaterialandInformationFlows,MaterialflowthemovementofmaterialthroughthefactoryInformationflowanotherflowassociatedwithproductionthattellseachprocesswhattomakeordonext,ValueStreamMappingSteps,ProductFamily,CurrentStateDrawing,WorkPlan,FutureStateDrawing,ValueStreamMappingSteps,ChooseaproductfamilyBeginbydrawingthecurrentstate(door-to-door)GatherinformationfromtheshopfloorDevelopmentofcurrentstateandfuturestateareoverlappingeffortsPrepareandbeginusinganimplementationplanRepeatwhenfuturestatebecomescurrentstate,ProductFamily,GatherData,Manufacturing,Transactional/Office,TypicalProcessData,CycletimeChangeovertimeProductionbatchsizesNumberofproductvariationsNumberofoperatorsPacksizeWorkingtime(minusbreaks)ScraprateOn-demandmachinetime,MaptheFlowofItems,usethisboxtorepresenteachprocessstepusethissymbolforcustomersandsuppliersusethissymboltorepresentasupermarket(first-in-first-out),usethissymbolforstoredinventory(knownquantities)usethissymbolforpushedinventory(arrowimpliesWIP)usethissymbolforapullsystemusethissymbolforafirst-in-first-outflowlaneusethissymbolfortransportation,FIFOmax10,MapFlowofInformation,usethissymbolformanualflowofinformationusethissymbolforelectronicflowofinformationusethissymboltorepresentinformationthatflows(suchasschedulesequence),usethissymbolforpullsystempapertriggerusethissymbolforapullsystemreturnablecontainertriggerusethissymbolforpullsystemtriggerataparticularquantitylevelusethissymbolforpullsystemgoseetriggerusethissymbolforpullsysteminformationstoragepoints,MappingTips,Alwayscollectcurrent-stateinformationwhilewalkingtheactualmaterialandinformationflowsyourself.Startwithaquickwalkalongtheentiredoor-to-doorvaluestreamthengobackandgatherdataateachprocessBeginattheshippingendandworkupstreamMeasureyourowntimesdontrelyonstandardtimes,olddatainafile,orhearsayEvenifseveralpeopleareinvolved,mapthewholevaluestreamyourselfUsebutcherpaperandmarkers,CurrentStateValueStreamMap,CurrentStateMapBytheNumbers,Startwiththecustomerplaceintheupperright-handcornerofthemapShowthecustomersrequirementsinadataboxDrawthebasicproductionprocessesindicateaprocessbyusingaprocessboxdrawmaterialflowfromlefttorightonthebottomhalfofthemapCollectdatathatwillbeimportantfordecidingwhatthefuturestatewillbedrawadataboxundereachprocessbox,ValueStreamMap,ValueStreamMap,CurrentStateMapBytheNumbers,NoteplacesinthematerialflowwhereinventoryaccumulatesdrawaninventorytriangletonotethelocationandamountofinventoryDrawthemovementofproducttothecustomerandnotefrequencyDrawthesupplier(s)intheupperlefthandcornerofthemapnotepacksizeanddeliveryfrequency,CurrentStateMapBytheNumbers,DrawtheinformationflowfromrighttoleftinthetophalfofthemapShowtheinformationflowusinganarrowthatislabeledwithnode-boxthisnodedescribestheinformationflowarrowUseseparatelinefordifferentinformationflows(e.g.,forecastsanddailyorders)Useaprocessboxtodenoteanyprocesseswithintheinformationflow,CurrentStateMapBytheNumbers,UseastripedarrowinthematerialflowpartofthemaptodenoteapushmovementofmaterialDrawatimelineIdentifymaterialmovementsthatarepushedbytheproducer,notpulledbythecustomerthiscanbedoneasyoufigureouthoweachprocessknowswhattomakeforitscustomerprocessandwhentomakeitDrawatimelineundertheprocessboxesandinventorytrianglestocompiletheproductionleadtime,ProductionLeadTime,Theleadtimecomponentforaprocessboxisthecycle-timeforaparttogothroughtheprocessLeadtimes(indays)foreachinventorytrianglearecalculatedas:(inventoryquantity)x(takttime)/(availableworktimeperday),ATaktTimeReminder,Takttime=(youravailableworktimepershift)/(customerdemandpershift)Availableworkingtimeexcludesbreaks,lunch,etc.andisrecordedinsecondsCustomerdemandisrecordedinunitsorpiecesTakttimedenotestherateatwhichacustomerbuysoneproduct,TIMELINE,CreateatimelineacrossthebottomofyourValueStreamMapTheUppertimeshouldbeyourNon-ValueaddedtimeortheamountoftimetheproductiswaitingforprocessingTheLowertimeshouldbeValueAddedtimeortheamountofprocessingtime,Waste,Theelementsofproductionthataddnovaluetotheproduct.Thingstorememberaboutwaste:Wasteisreallyasymptom,notarootcauseWastepointstoproblemsinthesystemToeliminatewaste,findandaddresstherootcause,ActivityProductivity,The8DeadlyWastesOverproductionProductDefectsInventoryExcessProcessTransportationExcessMotionWaitingUnder-utilizingPeople,Everybodysbusy!,Butwearestillnotdelivering!,Wheredoesallthateffortgo?,Howmanyoperators?,QuestionsfortheFutureState,Whatisthetakttime,basedontheavailableworkingtimeofyourdownstreamprocessesthatareclosettothecustomer?Wherecanyouusecontinuousflowprocessing?Whatisthepacemakerproductionprocessthatyouwillschedule?Wherewillyouneedtointroducesupermarketpullsystemsinordertocontrolproductionofupstreamprocesses?,SomeDefinitions(viaanExample),Customer,OnePieceFlow,FIFOlane,Pull,Supermarket,Pacemaker,QuestionsfortheFutureState,Willyoubuildtoafinishedgoodsupermarketfromwhichthecustomerpulls,ordirectlytocustomerorder?Howwillyouleveltheproductmixatthepacemakerprocess?Whatincrementofworkwillyouconsistentlyreleaseandtakeawayatthepacemakerprocess?Wh