value Stream map.ppt

1、Value Stream Mapping价值流图析,2004.03.20,161,第九章,Part I: Current State Mapping第一部分：现状图,Production Control,Scheduling,Customer客户,Suppliers 供应商,Purchasing,? Materials ? Manpower ? Priority,Manpower Available,Make Parts,Paint Dept,Material Available,Storage,Storage,Need Parts,161,Process Mapping Benefits过程

2、图的优点,Obtain current plant operating information 获得当前车间的业务资料 Obtain current metrics information 获得当前的数据资料 Identifies inventory and where it is stored 区分在库及其地点 Shows material flow表明原料的流动 Gives you a baseline on where you are and a tool to chart your progress after implementing improvements within the

3、plant在车间内实行改进后，给你一个绘制你进步的基点和工具,Objectives for Value Stream Analysis价值流析的目标,Understand the benefits of process mapping理解过程图的优点 Develop a process map using icons用图标来绘制过程图 Understand how the process map will be used to develop current state baselines, stretch objectives and improvement actions理解怎样用过程图来

4、发展当前状态基线，展望远景和改进行为。,Aging,9 天,礼拜四,礼拜二/礼拜四,2 天,15 天,3 天 (0.5天),3 天,钢铁供应商,礼拜一/三/五,压合工程,热合工程,顾客B,顾客 A,生产控制,每月订单,3 件产品 7 天 - 3 班/星期 批量生产 - 1 个星期的量 转换时间 - 4 小时 转换的频率 - 7 个班 不良率 - 7% 停机时间比率 -11% “Y” Avg. strokes/hour,月需求量 - 18,000 节拍时间=60” 理想周期=360” 不良率-3% 重修率-20% 停机时间比率 10% 2 hrs OT 56 件/月-人,月需求量 - 18,00

5、0 生产时间 450分钟每班 2 班 20 天每个月 节拍时间=60” 理想周期 = 240” 不良率-7% 重修率- 12% 9 件/月-人,制造工程,焊接工程,Example of a Current State Map,9 天,9 天,Definition定义,A Value Stream is the collection of all activities required to produce a product. This includes all activities, including those that add value and those that do not.价

6、值流是制造产品所必需的全部活动的集中 。这就包括了产生价值和不产生价值的全部活动。,The BIG Picture整体性,Using the value stream analysis means working on the big picture, not just the individual processes; improving the whole, not just optimizing the parts.运用价值流分析意味着在整体上工作，不仅仅是个别的生产过程；不只是优化局部而是提高全部。,Our Scope我们的范围,For this lesson, we will be

7、focusing on the “door-to-door” production flow inside our plant. That includes Receiving and Shipping.这里我们将把重点放在工厂车间与车间的生产流程上面。它包括接收和货运,T o t a l V a l u e S t r e a m价值流,O u r F o c u s重点,Suppliers 供货商,Our Plant and/or Company 车间或公司,Customer 顾客,Our Scope (contd)我们的范围（续）,As your experience grows, yo

8、u can expand outward to include the flow from suppliers to customers.随着经验的增长，你能够向外扩展到包括从供货商到消费者的连续流。 Likewise, our efforts will not get into the details of each departments specifics of operation.同样的，我们的重点不会陷入获取每个部门详细的操作细节。,This is not a computer process这不是一个使用计算机的过程,Value Stream Mapping is a pencil

9、 and paper tool that helps you to see and understand the flows of material and information as a product makes its way through the value stream.价值流图是以笔和纸为工具来帮助你在产品通过价值流时看清和理解物料和信息的流向。,Material and Information Flow材料和信息流,The movement of material is usually what comes to mind when we discuss “productio

10、n flow”.当我们谈论产品流程时，通常想到的是材料的流动。 But there is another flow - of information - which tells each process what to make or do next。但还有一种-信息流，它能告诉你每个过程做什么和将要做什么。 You must map both of them.你必须同时图析他们,Production Flow,information,material,Using the Mapping Tool 运用图析工具,First, we draw the current state map by g

11、athering information directly from the shop floor.首先，我们应运用从车间直接采集的信息来绘制现在状态图。,Product Family 产品系列,Current State Drawing现状图,Future State Drawing将来图,Work Plan计划,Using the Mapping Tool,From this, we begin to draw our ideal, or improved, operation; our Future State Map.从这里我们开始画理想和改良的操作；我们的将来状态图。,Using t

12、he Mapping Tool,The final step is to implement a plan to transition the plant from the current state to the future state.最后的步骤是执行从现在到将来状态工厂转变的计划,Focus on one Product Family重点在一种产品,Drawing all your product flows on one map will too complicated.在一幅图里画出所有的产品太复杂。 Value Stream Mapping means walking and d

13、rawing the process steps (material and information) for one product family from door to door in the plant.价值流图析意味着从工厂的一个车间到另一个车间画出一种产品的生产步骤。,Drawing a Current State Map绘制一幅现状图,Mapping begins at the level of door-to-door flow in your plant.在你的工厂里门对门的流动水平下开始绘图。 Processing categories are identified rat

14、her than recording each and every step.过程种类的确定远胜于每个步骤的记录。 “Cutting”, “Welding”, “Stitching”切割，焊接，缝纫。,The Icons Used.所用图标,We use symbols, or icons, to represent processes and flow.我们用标记，图标来代替过程和流。,制造,合作公司,数据框,在库及数量,成品向顾客的流动,原材料在厂内的流动,顺序生产流,公路运输(每周几次),运输途径(多长时间),原材料被下个工序拉动,指导生产信息流,A,B,C,(产品)市场,Aging,必

15、须在库时间,手工信息流,电子信息流,Drawing the Current State Map绘制现状图,An Example:一个实例： Acme Manufacturing produces widgets. The widgets are produced in two versions: style-type “A” and style-type “B”. The A style has a left-hand mounting bracket and the B style has right-hand mounting bracket . There is no variabili

16、ty in the design beyond the versions of the mounting bracket.阿克米加工厂生产以中小部件。有两种型号：A和B型。A型有一个左侧的支架，B型有一个右侧的支架。除了左右侧之外，该产品在设计上没有区别。,Begin with the customers requirements.以顾客的要求开始,The customers assembly plant is represented with a factory icon placed in the upper right-hand portion of the map. Underneat

17、h, draw a data box recording the requirements of the customer.客户的公司以右上角的符号标志，下面画一个数据框来记录客户的要求。,Altona Assembly公司两班生产，每天都需要运输产品。一般每月需求12,000 A 和 6,400 B. State Street requests palletized returnable tray with 20 brackets in a tray and up to 10 trays on a pallet.,Raw Hsg 5 days,20,000 A 15,000 B,25,000

18、 A 18,000 B,15,000 A 8,000 B,The next step is to draw the basic production processes. To indicate a process we use a process box. Under each processing step, we write within the data box key information: the cycle time, the changeover time, and the uptime.下一步是绘制基本生产过程。我们用一个过程框来表示一个过程。在每个过程，我们在数据框里写下

19、重要信息：周期时间，换型时间和可靠性。,As you walk the material flow you will find places where inventory accumulates. These points are where the flow is stopping. We indicate this with tombstones to indicate “dead” flow.,Show Processes in our plant绘制工厂里的各个过程,Include the suppliers包括供应商,Raw Hsg 5 days,20,000 A 15,000 B

20、,25,000 A 18,000 B,15,000 A 8,000 B,Port Casting,Tues & Thurs,At the other end, we represent the casting supplier with another factory icon. We use the truck icon and broad arrow to show movement of material from the supplier to our plant.,The Information Flow信流,The Production Control Department is

21、drawn with a process box.用一个过程框表示生产管理科。 Production Control collects information from its customers and sends specific instructions to each manufacturing process about what it should produce.生产管理可从客户那里收集信息并下达详细的生产指令给每一个生产过程，告诉他们应生产什么。,The Information Flow信息流,Raw Hsg 5 days,20,000 A 15,000 B,25,000 A 18