价值流VSM培训--如何绘制和制作价值流图(步骤)

©TheTimkenCompany(example)HomeCenter11,400/Mo.Flat3,500/Mo.Phil.745/day20box/palletDailyBetty’s2XWeeklyPete’sWeekly1500lbcoils500lbBox3mo.ForecastDailyOrdersMRPProductionControlWeeklyScheduleDailyShipSchedule6wkFcastWeeklyFAX10days1.5sec40sec71sec54sec59sec24.1days5.8days4.3days7days7daysProductionLeadTime58.2daysValueAddedTime225.5sec.4,400flat800phillipsSHIPPINGStagingAssemblyMark1.5secCT90minc/o80%U/T2shiftsPressMaterialStoresAreaCoils10daysHandles6days10,000flat8,000phillips3,200flat1,100phillips2,200flat1,000phillips1,200flat4,000phillips111SubAssy2SubAssy11IIIIII40secCT5minc/o100%U/T2shifts71secCT5minc/o100%U/T2shifts54secCT10minc/o90%U/T2shifts59secCT5minc/o100%U/T2shifts(10,000+8,000)/745=24.1days(example)ProductionControl3mo.ForecastDailyOrders202020DailyOrder20PressHomeCenterDailySHIPPINGStagingAssyCellTakt=70secC/O=0Uptime=100%2shiftsTotalworkcontent210secFP20C/O10min1.5days1day2days1.5sec210secProductionleadtime=4.5daysValueaddedtime=211.5sec6wkFcastDailyOrderPete’sDaily500lbBoxCoils1.5DaysBetty’sDaily1500lbcoilsHandles1.5DaysCopyrightRockwellAutomation2000(bothvalueaddedandnon-valueadded)requiredtobringaproductthroughthemainflowsessentialtoeveryproduct.Productionflowfromrawmaterialintothearmsofthecustomer.Designflowfromconcepttolaunch.FinishedProductRawMaterialStampingAssemblyCellWeldingProcessProcessProcess………………...ItisjustatoolWhat’simportantiscreatingavalue-addingflow.Usethetooltohelpyousee“icons”areusedtorepresentprocessesandflows.Keepthemconsistentforclearcommunication(1)Safetystockoperatorinfoflowdataboxfinishprodtocust.loadlevelingstockvisualcalendarkaizenKanbanlotsDrawingaCurrentStateMap(cont.)(2)DrawingaCurrentStateMapDenotessharedprocess•C/T(cycletime):timethatelapsesbetweenonepartcomingofftheprocesstothenextpartcomingoff,inseconds;•C/O(changeovertime)•Uptime(on-demandmachineuptime)•Availableworkingtime:inseconds,minusbreak,meeting,andcleanuptimes);•EPE(everypartevery__)•Numberofoperators(C/T):Howoftenapartorproductactuallyiscompletedbyaprocess,astimedbyobservation.Also,thetimeittakesanoperatortogothroughalloftheirworkelementsbeforerepeatingthem.(C/T)VATimeCycleTimeLeadTimeValueAddedTime(VA):Timeofthoseworkelementsthatactuallytransformtheproductinawaythatthecustomeriswillingtopayfor.Leadtime(L/T):Thetimeittakesonepiecetomoveallthewaythroughaprocessoravaluestream,fromstarttofinish.Envisiontimingamarkedpartasitmovesfrombeginningtoend.•Tools:1.Ablanksheetof“A3”paper2.Apencil•Company:AcmeStamping•Productfamily:AStamped-steeringbracket•Twoversions:1.Left-hand-sidedrivecars2.Right-hand-sidedrivecars•Supplier:MichiganSteelCo.(CoilSteel)•Customer:StateStreetAssemblyplant•Stamping•Spot-WeldingWorkstation1•Spot-WeldingWorkstation2•AssemblyWorkstation1•AssemblyWorkstation2•(Shipping)•Thesupplier’spacksizeisa500footrollofcoiledsteel;•5daysofCoilsforstock•Leadtimes(indays)foreachinventorytrianglearecalculatedasfollows:inventoryquantitydividedbythedailycustomerrequirement.•Value-addingtimeistheprocessingtime;(example)CopyrightRockwellAutomation2000‘TAKT’comesfromtheGermanwordmeaning‘meter.’TAKTTimeiscalculatedbydividingthenumberofeffectivehoursinaday(numberofworkhoursminusbre