Value Stream Mapping精益生产PPT学习教案

1、会计学1Value Stream Mapping精益生产精益生产Value Stream Mapping2第1页/共91页Value Stream Mapping3第2页/共91页Value Stream Mapping4the organization.第3页/共91页Value Stream Mapping5第4页/共91页Value Stream Mapping6第5页/共91页Value Stream Mapping7nDriver for results 第6页/共91页Value Stream Mapping88ProductionControlASSEMBLY 20,000 pc

2、s/moModule=100SUPPLIERDISTAssemblyAssemblyForgeMachineRaw materialDaily scheduleForge materialDaily schedule Bolts, nuts, washers Daily scheduleO-ring, bearing, snap ring Daily scheduleWarehouseReceiving6 Month ForecastWeekly FaxMRP90/60/30 DayDaily OrderDaily Release2/Day1/WeekCustomerC/T = 30 SecC

3、/O = 30 MinUptime 75%Batch Size 100C/T = 45 SecC/O = 60 MinUptime 95%Batch Size 100C/T = 60 SecC/O = 5 MinUptime 95%Batch Size 100C/T = 50 SecC/O = 10 MinUptime 95%Batch Size 1001000 pcs5000 pcs100 pcs200 pcs30 sec60 sec45 sec50 sec15 hours83 hours2 hoursProcessing time = 185 seconds4 hoursProductio

4、n lead time = 104 hours 3 min第7页/共91页Value Stream Mapping99ProductionControlASSEMBLY 20,000 pcs/moModule=100SUPPLIERDISTAssemblyAssemblyForgeMachineWarehouseReceiving6 Month ForecastDaily Order90/60/30 DayDaily Order2/DayDailyCustomerC/T = 30 SecC/O = 30 MinUptime 95%Batch Size 100C/T = 45 SecC/O =

5、10 MinUptime 95%Batch Size 100C/T = 60 SecC/O = 5 MinUptime 95%Module Size100C/T = 50 SecC/O = 10 MinUptime 95%Module Size 100200 pcs500 pcsMax 100 pcsMax 200 pcs30 sec60 sec45 sec50 sec2.5 hours 10 hours2 hoursProcessing time = 185 seconds4 hoursProduction lead time = 18 hours 33 minSet-up Reductio

6、nBatchBinDaily OrderTPMModuleFIFOFIFOMatMat1) Set-up reduction2) Pull Systems3) TPM第8页/共91页第9页/共91页Value Stream Mapping11OUTPUTPROCESSCUSTOMERSUPPLIERINPUTSIPOC chartTop Down Process FlowVSMCompanyMult. PlantsSingle PlantRouter StepsProcess StepsI22I48450 Per Day400 Min Avail1 ShiftC/T 7 Min180 Per

7、Day1200 Min Avail3 ShiftC/T 3 MinStep 22Step 31Step 14300 Per Day400 Min Avail1 ShiftC/T 12 Min第10页/共91页第11页/共91页Value Stream Mapping13A high-level SIPOC chart helps to identify the process output(s) and the customers of that output so that the Voice of the Customer can be captured第12页/共91页Value Str

8、eam Mapping14OUTPUTPROCESSCUSTOMERRequirements, Specifications and InformationSUPPLIERINPUTBoundary -(“Triggers” Process)Boundary -(ProcessCompleted)第13页/共91页Value Stream Mapping15OUTPUTPROCESSCUSTOMERSUPPLIERINPUTCustomer RequirementsQualityOn-time DeliveryCostBusinessRequirementsReduced InventoryI

9、ncreased Throughput第14页/共91页第15页/共91页第16页/共91页Value Stream Mapping18第17页/共91页Value Stream Mapping19T h e P r o c e s sThe Sub-ProcessThe Micro-Process第18页/共91页Value Stream Mapping20第19页/共91页第20页/共91页Value Stream Mapping22第21页/共91页Value Stream Mapping23ReceivingStampingDrill MillGrindDrillPressPaintC

10、urePackAxxxxxxxxxBxxxxxxxxxCxxxxxxxxxDxxxxExxxxFxxxxxGxxxxxProductsPROCESSES第22页/共91页第23页/共91页Value Stream Mapping25第24页/共91页Value Stream Mapping26MachiningProcess BoxData BoxIInventory1OperatorManualInformationElectronic InformationC/T = 36 SecSet Up Time 7 MinUptime 86%Batch Size 50Inspection Poin

11、tWithdrawalKanbanPush ArrowCustomers / SuppliersTo CustomerProductionKanbanSupermarketTruck ShipmentFuture State Improvement“Go See”SchedulingDailyScheduleSchedule第25页/共91页Value Stream Mapping27第26页/共91页Value Stream Mapping28ProductionControlASSEMBLY CUSTOMERProductionControlMACHINE SUPPLIERDIST28As

12、semblyAssemblyForgeMachineRaw materialDaily scheduleForge materialDaily schedule Bolts, nuts, washers Daily scheduleO-ring, bearing, snap ring Daily schedule第27页/共91页Value Stream Mapping29SupplierRaw MaterialsMRP transactionReceivingInspectionReceiving1UnpackBottlesUnpack1BottleWasherWasher1Fill & C

13、apFill1Heat ShrinkSealer1Labels onBottlesLabeler1PackProductDrop Pack1Labels on PackageLabel1Tag & CratePallet1Shrink Wrap& LoadShip1DistributionCenterCustomer888 Cases/Day37 Cases/HrIBottle Kits16 daysIWarehouseIIIILiquid Pharmaceutical Current State VSM第28页/共91页第29页/共91页Value Stream Mapping31Time:

14、 1 Hour第30页/共91页第31页/共91页第32页/共91页Value Stream Mapping34第33页/共91页Value Stream Mapping35ProductionControlASSEMBLY SUPPLIERDISTAssemblyAssemblyForgeMachineRaw materialDaily scheduleForge materialDaily schedule Bolts, nuts, washers Daily scheduleO-ring, bearing, snap ring Daily scheduleWarehouseReceivi

15、ngCustomer第34页/共91页Value Stream Mapping36SupplierRaw MaterialsMRP transactionReceiving0.5111InspectionReceiving1UnpackBottlesUnpack1BottleWasherWasher1Fill & CapFill1Heat ShrinkSealer1Labels onBottlesLabeler1PackProductDrop Pack1Labels on PackageLabel1Tag & CratePalletizer1Shrink Wrap& LoadShip1Dist

16、ributionCenterCustomer888 Cases/Day37 Cases/Hr11111Kit NeckRingsIBottle Kits16 daysIWarehouseIPowder III1ReceivingInspectionLot Sample1AnalyticalLabTesting2Off Load0.5Purify WaterTankCleanPrepSampleFill & MixRelease SolutionLabInspectionReceivingLab TestTestGrind1Tumbling1IVials 2 hrsICaps 4 hrsBott

17、le WasherWashBottle FillFillBottle CapCapKitting1RingSub-contractorIIIIIIIIBottle Kits16 daysIIILiquid Pharmaceutical Current State VSM第35页/共91页第36页/共91页Value Stream Mapping38nDocument how information is gathered, i.e.,electronic, manual, “go see”, etc.第37页/共91页Value Stream Mapping39ProductionContro

18、lASSEMBLY SUPPLIERDISTAssemblyAssemblyForgeMachineRaw materialDaily scheduleForge materialDaily schedule Bolts, nuts, washers Daily scheduleO-ring, bearing, snap ring Daily scheduleWarehouseReceiving6 Month ForecastWeekly FaxMRP90/60/30 DayDaily OrderDaily ReleaseCustomer第38页/共91页Value Stream Mappin

19、g40ProductionControlASSEMBLY 20,000 pcs/moModule=100SUPPLIERDISTAssemblyAssemblyForgeMachineRaw materialDaily scheduleForge materialDaily schedule Bolts, nuts, washers Daily scheduleO-ring, bearing, snap ring Daily scheduleWarehouseReceiving6 Month ForecastWeekly FaxMRP90/60/30 DayDaily OrderDaily R

20、elease2/Day1/WeekCustomer第39页/共91页Value Stream Mapping41Liquid Pharmaceutical Current State VSMSupplierRaw MaterialsMRP transactionReceiving0.5111InspectionReceiving1UnpackBottlesUnpack1BottleWasherWasher1Fill & CapFill1Heat ShrinkSealer1Labels onBottlesLabeler1PackProductDrop Pack1Labels on Package

21、Label1Tag & CratePalletizer1Shrink Wrap& LoadShip1DistributionCenterCustomer888 Cases/Day37 Cases/Hr11111Kit NeckRings2 weeksIFDA CheckBottle Kits16 daysIWarehouseIPowder 5 daysIIISolution BatchRecordChemical OrdersOrder SheetProductionPlanningActivatorFinished GoodsScheduleSchedule FromPlanning(Exc

22、el)EmergencyOrdersMRPSystem1ReceivingInspectionLot Sample1AnalyticalLabTesting2Off Load0.5Purify WaterTankCleanPrepSampleFill & MixRelease SolutionLabInspectionReceivingLab TestTestGrind1Tumbling1IVials 2 hrsICaps 4 hrsBottle WasherWashBottle FillFillBottle CapCapKitting1RingSub-contractorIActivator

23、Batch RecordIIIIIIIBottle Kits16 daysIII第40页/共91页第41页/共91页Value Stream Mapping43Time: 30 minutes第42页/共91页第43页/共91页第44页/共91页Value Stream Mapping46Frequency VariationAssemblyProcessing TimeLead TimeInventories: RM, WIP, FGDaily VolumeShiftsCost Per Unit: L, O, MVolumeFrequencyVariationCustomerFrequenc

24、yTimeDistanceCost第45页/共91页Value Stream Mapping47nOperating Time (Minus Breaks)nScrap RateC/T = 36 SecSet Up Time 7 MinUptime 86%Batch Size 50Data Box第46页/共91页Value Stream Mapping48第47页/共91页Value Stream Mapping49ProductionControlASSEMBLY 20,000 pcs/moModule=100SUPPLIERDISTAssemblyAssemblyForgeMachine

25、Raw materialDaily scheduleForge materialDaily schedule Bolts, nuts, washers Daily scheduleO-ring, bearing, snap ring Daily scheduleWarehouseReceiving6 Month ForecastWeekly FaxMRP90/60/30 DayDaily OrderDaily Release2/Day1/WeekCustomerC/T = 30 SecC/O = 30 MinUptime 95%Batch Size 100C/T = 45 SecC/O = 6

26、0 MinUptime 80%Batch Size 100C/T = 60 SecC/O = 5 MinUptime 95%Batch Size 100C/T = 50 SecC/O = 10 MinUptime 95%Batch Size 1001000 pcs5000 pcs100 pcs200 pcs第48页/共91页Value Stream Mapping50Liquid Pharmaceutical Current State VSMSupplierRaw MaterialsMRP transactionReceiving0.5111InspectionReceiving1Unpac

27、kBottlesUnpack1BottleWasherWasher1Fill & CapFill1Heat ShrinkSealer1Labels onBottlesLabeler1PackProductDrop Pack1Labels on PackageLabel1Tag & CratePalletizer1Shrink Wrap& LoadShip1DistributionCenterCustomer888 Cases/Day37 Cases/Hr11111Kit NeckRingsC/T 5 minutesC/O N/AOEE N/AAvailable Time 27,600 seco

28、ndsProcess time 5 minutesC/T 15 minutesC/O N/AOEE XX %Available Time 27,600 secondsProcess time 15 minutesC/T 20 minutesC/O N/AOEE XX %Available Time 27,600 secondsProcess time 20 minutesC/T 0.2 minutesC/O N/AOEE 98 %Available Time 27,600 secondsProcess time 0.2 minutesC/T 12 secondsC/O N/AOEE 99 %A

29、vailable Time 27,600 secondsProcess time 12 secondsC/T 35 minutesC/O 10 minutesOEE 97 %Available Time 27,600 secondsProcess time 35 minutesC/T 90 minutesC/O 180 minutesOEE 95 %Available Time 27,600 secondsProcess time 90 minutesC/T 45 minutesC/O N/AOEE XX %Available Time 27,600 secondsProcess time 3

30、5 minutesC/T 20 minutesC/O N/AOEE XX %Available Time 27,600 secondsProcess time 20 minutesC/T 10 secondsC/O 45 minutesOEE 96 %Available Time 27,600 secondsProcess time 10 secondsC/T 35 secondsC/O 30 minutesOEE 92 %Available Time 27,600 secondsProcess time 35 secondsC/T 120 minutesC/O 120 minutesOEE

31、88 %Available Time 27,600 secondsProcess time 2 minutesC/T 10 secondsC/O 30 minutesOEE 98 %Available Time 27,600 secondsProcess time 10 secondsC/T 10 secondsC/O 30 minutesOEE 99 %Available Time 27,600 secondsProcess time 10 secondsC/T 30 secondsC/O 1.5 hoursOEE 98 %Available Time 27,600 secondsProce

32、ss time 30 secondsC/T 10 secondsC/O 30 minutesOEE 99 %Available Time 27,600 secondsProcess time 10 secondsC/T 30 secondsC/O 30 minutesOEE 98 %Available Time 27,600 secondsProcess time 30 secondsC/T 40 minutesC/O N/AOEE XX %Available Time 27,600 secondsProcess time 40 minutesC/T 20 minutesC/O N/AOEE

33、XX %Available Time 27,600 secondsProcess time 20 minutesC/T 20 minutesC/O N/AOEE XX %Available Time 27,600 secondsProcess time 20 minutesC/T 180 minutesC/O N/AOEE 98 %Available Time 27,600 secondsProcess time 180 minutesC/T 75 minutesC/O N/AOEE 98 %Available Time 27,600 secondsProcess time 75 minute

34、sC/T 7 secondsC/O 30 minutesOEE 98 %Available Time 27,600 secondsProcess time 7 secondsC/T 2 secondsC/O 2 hoursOEE 85 %Available Time 27,600 secondsProcess time 2 secondsC/T 2 secondsC/O 15 minOEE 99 %Available Time 27,600 secondsProcess time 2 secondsC/T 25 minutesC/O 15 minOEE XX %Available Time 2

35、7,600 secondsProcess time 25 minutes2 weeksIFDA CheckBottle Kits16 daysIWarehouseIPowder 5 daysIIISolution BatchRecordChemical OrdersOrder SheetProductionPlanningActivatorFinished GoodsScheduleSchedule FromPlanning(Excel)EmergencyOrdersMRPSystem1ReceivingInspectionLot Sample1AnalyticalLabTesting2Off

36、 Load0.5Purify WaterTankCleanPrepSampleFill & MixRelease SolutionLabInspectionReceivingLab TestTestGrind1Tumbling1IVials 2 hrsICaps 4 hrsBottle WasherWashBottle FillFillBottle CapCapKitting1RingSub-contractorIActivatorBatch RecordIIIIIIIBottle Kits16 daysIII第49页/共91页第50页/共91页Value Stream Mapping52Ti

37、me: 30 minutes第51页/共91页第52页/共91页第53页/共91页Value Stream Mapping5516 hours1 hour2 hours1 day40 hours1 hour8 hours16 hours8 hoursProduction Lead Time = 91 hoursProcessing Time = 4 hours 第54页/共91页Value Stream Mapping56SupplierRaw MaterialsMRP transactionReceiving0.5111InspectionReceiving1UnpackBottlesUnp

38、ack1BottleWasherWasher1Fill & CapFill1Heat ShrinkSealer1Labels onBottlesLabeler1PackProductDrop Pack1Labels on PackageLabel1Tag & CratePalletizer1Shrink Wrap& LoadShip1DistributionCenterCustomer888 Cases/Day37 Cases/Hr11111Kit NeckRingsC/T 5 minutesC/O N/AOEE N/AAvailable Time 27,600 secondsProcess

39、time 5 minutesC/T 15 minutesC/O N/AOEE XX %Available Time 27,600 secondsProcess time 15 minutesC/T 20 minutesC/O N/AOEE XX %Available Time 27,600 secondsProcess time 20 minutesC/T 0.2 minutesC/O N/AOEE 98 %Available Time 27,600 secondsProcess time 0.2 minutesC/T 12 secondsC/O N/AOEE 99 %Available Ti

40、me 27,600 secondsProcess time 12 secondsC/T 35 minutesC/O 10 minutesOEE 97 %Available Time 27,600 secondsProcess time 35 minutesC/T 90 minutesC/O 180 minutesOEE 95 %Available Time 27,600 secondsProcess time 90 minutesC/T 45 minutesC/O N/AOEE XX %Available Time 27,600 secondsProcess time 35 minutesC/

41、T 20 minutesC/O N/AOEE XX %Available Time 27,600 secondsProcess time 20 minutesC/T 10 secondsC/O 45 minutesOEE 96 %Available Time 27,600 secondsProcess time 10 secondsC/T 35 secondsC/O 30 minutesOEE 92 %Available Time 27,600 secondsProcess time 35 secondsC/T 120 minutesC/O 120 minutesOEE 88 %Availab

42、le Time 27,600 secondsProcess time 2 minutesC/T 10 secondsC/O 30 minutesOEE 98 %Available Time 27,600 secondsProcess time 10 secondsC/T 10 secondsC/O 30 minutesOEE 99 %Available Time 27,600 secondsProcess time 10 secondsC/T 30 secondsC/O 1.5 hoursOEE 98 %Available Time 27,600 secondsProcess time 30

43、secondsC/T 10 secondsC/O 30 minutesOEE 99 %Available Time 27,600 secondsProcess time 10 secondsC/T 30 secondsC/O 30 minutesOEE 98 %Available Time 27,600 secondsProcess time 30 secondsC/T 40 minutesC/O N/AOEE XX %Available Time 27,600 secondsProcess time 40 minutesC/T 20 minutesC/O N/AOEE XX %Availab

44、le Time 27,600 secondsProcess time 20 minutesC/T 20 minutesC/O N/AOEE XX %Available Time 27,600 secondsProcess time 20 minutesC/T 180 minutesC/O N/AOEE 98 %Available Time 27,600 secondsProcess time 180 minutesC/T 75 minutesC/O N/AOEE 98 %Available Time 27,600 secondsProcess time 75 minutesC/T 7 seco

45、ndsC/O 30 minutesOEE 98 %Available Time 27,600 secondsProcess time 7 secondsC/T 2 secondsC/O 2 hoursOEE 85 %Available Time 27,600 secondsProcess time 2 secondsC/T 2 secondsC/O 15 minOEE 99 %Available Time 27,600 secondsProcess time 2 secondsC/T 25 minutesC/O 15 minOEE XX %Available Time 27,600 secon

46、dsProcess time 25 minutes2 weeksIFDA CheckBottle Kits16 daysIWarehouseIPowder 5 daysII5 days20 min16 days16 days5 min5 min2 weeks20 min180 min75 min7 sec2 sec2 sec25 min2 secs1 weekVA = 320.2 MinLT = 52 Days20 min10 sec35 sec2 min10 sec10 sec30 sec30 sec60 sec40 minVA = 25.6 MinLT = 64.1 Days43 days

47、1 week30 sec5 min16 daysISolution BatchRecordChemical OrdersOrder SheetProductionPlanningActivatorFinished GoodsScheduleSchedule FromPlanning(Excel)EmergencyOrdersMRPSystem1ReceivingInspectionLot Sample1AnalyticalLabTesting2Off Load0.5Purify WaterTankCleanPrepSampleFill & MixRelease SolutionLabInspe

48、ctionReceivingLab TestTestGrind1Tumbling1IVials 2 hrsICaps 4 hrsBottle WasherWashBottle FillFillBottle CapCapKitting1RingSub-contractorIActivatorBatch RecordIIIIIIIBottle Kits16 daysIII5 min2 days15 min20 min12 sec35 min90 min35 min4 hours4 hoursVA = 200.2 minLT = 3.4 DaysLiquid Pharmaceutical Curre

49、nt State VSM第55页/共91页第56页/共91页第57页/共91页第58页/共91页Value Stream Mapping60第59页/共91页第60页/共91页Value Stream Mapping62第61页/共91页Value Stream Mapping63第62页/共91页Value Stream Mapping64第63页/共91页Value Stream Mapping65第64页/共91页Value Stream Mapping66第65页/共91页Value Stream Mapping67第66页/共91页Value Stream Mapping68第67页

50、/共91页Value Stream Mapping69第68页/共91页Value Stream Mapping70167168125210160507090110130150170190210230 Front Diff./Drive Shaft Torque Exhaust Manifold Install Oxygen Sensor Starter Cables, Torque Diff. Trans Wire HarnessSeconds Per PieceCycle time 210 sec/pcTakt Time 170 sec/pcConstraintUnbalancedTakt

51、 Time = 170 seconds/pc第69页/共91页Value Stream Mapping71第70页/共91页Value Stream Mapping72第71页/共91页Value Stream Mapping73第72页/共91页Value Stream Mapping74第73页/共91页Value Stream Mapping75第74页/共91页Value Stream Mapping7676ProductionControlASSEMBLY 20,000 pcs/moModule=100SUPPLIERDISTAssemblyAssemblyForgeMachineW

52、arehouseReceiving6 Month ForecastDaily Order90/60/30 DayDaily Order2/DayDailyCustomerC/T = 30 SecC/O = 30 MinUptime 95%Batch Size 100C/T = 45 SecC/O = 10 MinUptime 95%Batch Size 100C/T = 60 SecC/O = 5 MinUptime 95%Module Size100C/T = 50 SecC/O = 10 MinUptime 95%Module Size 100200 pcs500 pcsMax 100 p

53、csMax 200 pcs30 sec60 sec45 sec50 sec2.5 hours 10 hours2 hoursProcessing time = 185 seconds4 hoursProduction lead time = 18 hours 33 minSet-up ReductionBatchBinDaily OrderTPMModuleFIFOFIFOMatMat1) Set-up reduction2) Pull Systems3) TPM第75页/共91页Value Stream Mapping77第76页/共91页Value Stream Mapping78第77页

54、/共91页Value Stream Mapping79Future State VSMProductionControlASSEMBLY 20,000 pcs/moModule=100SUPPLIERDISTAssemblyAssemblyForgeMachineWarehouseReceiving6 Month ForecastDaily Order90/60/30 DayDaily Order2/DayDailyCustomerC/T = 30 SecC/O = 30 MinUptime 95%Batch Size 100C/T = 45 SecC/O = 10 MinUptime 95%

55、Batch Size 100C/T = 60 SecC/O = 5 MinUptime 95%Module Size100C/T = 50 SecC/O = 10 MinUptime 95%Module Size 100200 pcs500 pcsMax 100 pcsMax 200 pcs30 sec60 sec45 sec50 sec2.5 hours 10 hours2 hoursProcessing time = 185 seconds4 hoursProduction lead time = 18 hours 33 minSet-up ReductionBatchBinDaily O

56、rderTPMModuleFIFOFIFOMatMatPacemaker LoopProcess LoopSupplier Loop1) Pacemaker Loop2) Process Loop3) Supplier Loop第78页/共91页Value Stream Mapping80Date: TODAYPrepared by:Value StreamScrewBeesYear: _Joe OptimistPlant Level ObjectiveV.S. LoopValue Stream ObjectiveGoal123456789101112Person Resp.CommentsI

57、mprove ScrewBee ProfitContinuous FlowZero WIPReduce ScrewBee Lead timeReduce CT210 sec. or lessHave more funReduce C/OZeroPlay more golf1Improve Uptime100%Develop pull system2 days FGIPull System at Press1 day InventoryPull with no schedule2Reduce C/O10 minutes or lessReduce Batch sizes570 flat, 175

58、 phillipsDevelop Pull system 1.5 days of inventory Get daily deliveries3YEARLY VALUE STREAM PLANMONTHLY SCHEDULE2001Need SMED training before KaizenSingle piece flow event Januaryand March.Establish TPM owner and start with focused improvement.Collect data to calculate Kanban.Purchase returnable con

59、tainers.Conduct SMED event; include planners to assure lot size decrease along with set-upreduction.Conduct Kanban training forSuppliers.Contact other area factoriesto organize cooperative milkruns.One-Piece PaulSally SMEDKarl KanbanPressroom TeamHarvey Mackay第79页/共91页Value Stream Mapping81第80页/共91页

60、Value Stream Mapping82Liquid Pharmaceutical Future State VSMSupplierRaw MaterialsMRP transactionReceiving0.5111InspectionReceiving1UnpackBottlesUnpack1BottleWasherWasher1Fill & CapFill1Heat ShrinkSealer1Labels onBottlesLabeler1PackProductDrop Pack1Labels on PackageLabel1Tag & CratePalletizer1Shrink