精益生产之价值流图Value-Stream-Mapping

MeasureAnalyzeControlImproveDefineValueStreamMappingDefineValueStreamMapping2AgendaMondayKick-OffIntroductionsCurrentStateSteps1-4TuesdayCurrentStateSteps5-7WednesdayCurrentStateSteps8-9IdentifyandPrioritizeImprovementOpportunitiesCreateFutureStateThursdayPrepareforPresentationPresentationDefineValueStreamMapping3LearningObjectivesThelearningobjectivesforthiscourseare:BeabletocreateCurrentStateandFutureStateValueStreamMapsBeabletousecustomerandbusinessrequirementstoprioritizeimprovementopportunitiesThelearningobjectiveforthiscourseisnot:ToteachLeanToolstohelpachieveFutureStateDefineValueStreamMapping4What’sinItforMe?Valuestreammappingisavisualtooltohelpunderstandthecurrentvaluestream.Itallowspeopletoeasilyunderstandwherewasteexistsintheprocess.Itgivestheteamabasisforprioritizingimprovementefforts.Itgivestheteamavisualtoolforrepresentingtheirimprovementideas,sotheyarebetterabletocommunicatewithpeopleinsideandoutsidetheorganization.DefineValueStreamMapping5TeachingApproachTeachappropriateValueStreamMappingstepShowsimplifiedexampleShowcomplexrealworldexampleWorkB&DIndustriesExerciseinteamsApplylearningtoFlygtprocessDefineValueStreamMapping6ValueStreamMappingProcessStepsIdentifyCurrentStateStep1:SIPOCChartStep2:TopDownFlowChartStep3:DetermineProductFamilyStep4:DrawProcessFlowStep5:DrawMaterialFlowStep6:DrawInformationFlowStep7:ProcessDataCollectionStep8:AddProcessandLeadTimedataStep9:VerifyCurrentStateMapIdentifyandPrioritizeImprovementOpportunitiesDetermineFutureStateImplementImprovementstoAchieveFutureStateDefineValueStreamMapping7ValueStreamManagerAssignValueStreamManagerOnepersontomanagethemappingofthetotalflowHasthecapabilitytomakechangesacrossdepartmentalboundariesLeadsthecreationandprioritizationoftheimplementationplanforgettingfrompresentstatetofuturestateMonitorsimplementationandupdatesimplementationplanDriverforresultsDefineValueStreamMapping8CurrentStateVSM8ProductionControlASSEMBLY20,000pcs/moModule=100SUPPLIERDISTAssemblyAssemblyForgeMachine•Rawmaterial•Dailyschedule•Forgematerial•Dailyschedule•Bolts,nuts,washers•Dailyschedule•O-ring,bearing,snapring•DailyscheduleWarehouseReceiving6MonthForecastWeeklyFaxMRP90/60/30DayDailyOrderDailyRelease2/Day1/WeekCustomerC/T=30SecC/O=30MinUptime75%BatchSize100C/T=45SecC/O=60MinUptime95%BatchSize100C/T=60SecC/O=5MinUptime95%BatchSize100C/T=50SecC/O=10MinUptime95%BatchSize1001000pcs5000pcs100pcs200pcs30sec60sec45sec50sec15hours83hours2hoursProcessingtime=185seconds4hoursProductionleadtime=104hours3minDefineValueStreamMapping9FutureStateVSM9ProductionControlASSEMBLY20,000pcs/moModule=100SUPPLIERDISTAssemblyAssemblyForgeMachineWarehouseReceiving6MonthForecastDailyOrder90/60/30DayDailyOrder2/DayDailyCustomerC/T=30SecC/O=30MinUptime95%BatchSize100C/T=45SecC/O=10MinUptime95%BatchSize100C/T=60SecC/O=5MinUptime95%ModuleSize100C/T=50SecC/O=10MinUptime95%ModuleSize100200pcs500pcsMax100pcsMax200pcs30sec60sec45sec50sec2.5hours10hours2hoursProcessingtime=185seconds4hoursProductionleadtime=18hours33minSet-upReductionBatchBinTPMModuleFIFOFIFOMatMat1)Set-upreduction2)PullSystems3)TPMMeasureAnalyzeControlImproveDefineValueStreamMappingSIPOCTop-DownMapValue-StreamMappingDefineValueStreamMapping11ProcessMappingHierarchyOUTPUTPROCESSCUSTOMERSUPPLIERINPUTSIPOCchartTopDownProcessFlowVSMCompanyMult.PlantsSinglePlantRouterStepsProcessStepsI22I48450PerDay400MinAvail1ShiftC/T7Min180PerDay1200MinAvail3ShiftC/T3MinStep22Step31Step14300PerDay400MinAvail1ShiftC/T12MinMeasureAnalyzeControlImproveDefineStep1SupplierInputProcessOutputCustomer(SIPOC)MapDefineValueStreamMapping13Step1:High-LevelSIPOCChartSupplierInputProcessOutputChart(SIPOC)Customers:CompaniesX,Y,&ZOutputs:Cost,Quality,On-TimeDeliveryProcess:ProduceProducts1,2,3,4&5Inputs:RawMaterialSuppliers:CompaniesA,B&CAhigh-levelSIPOCcharthelpstoidentifytheprocessoutput(s)andthecustomersofthatoutputsothattheVoiceoftheCustomercanbecapturedDefineValueStreamMapping14OUTPUTPROCESSCUSTOMERRequirements,SpecificationsandInformationSUPPLIERINPUTBoundary-(“Triggers”Process)Boundary-(ProcessCompleted)Step1:TheSIPOCChartTranslateCustomerrequirementsintooutputspecificationsandidentifyrelatedKeyProcessOutputVariables(KPOVs)GoUpsteamtotheProcessSteps(s)whichmostimpacttheOUTPUTanddeterminetheKeyProcessInputVariables(KPIVs)TrytouseLeadingMeasure(s)(insteadofLaggingMeasures–iflagging,thenClose/ReduceamountofLagging)DefineValueStreamMapping15Step1:SIPOCBusinessRequirementsNotonlyshouldtheSIPOCchartcapturecustomerrequirements,butalsothekeyBusinessRequirementsaswell.OUTPUTPROCESSCUSTOMERSUPPLIERINPUTCustomerRequirements•Quality•On-timeDelivery•CostBusinessRequirements•ReducedInventory•IncreasedThroughputMeasureAnalyzeControlImproveDefineStep1SIPOCChartB&DIndustriesExerciseMeasureAnalyzeControlImproveDefineStep2TopDownProcessFlowDefineValueStreamMapping18Step2:Top-DownProcessFlowPurposeThepurposeoftheTop-DownProcessFlowistodeterminethecorrectleveltoValueStreamMap.Itiscriticaltoourbusinesstofocusourimp