Team5A-ALUETEMaterialReplenishmentImprovement(精益生

Design.Build.Ship.Service.1KaizenTemplates(SupplyChain)GBE-KPO-4-002-00Revision13ProjectTitle:ALUETEMaterialReplenishmentImprovementSite:FlextronicsNanjingLine/Area:3FSupermarketTeam#:Team5ADate:2011.3.7to2011.3.18Category:SupplyChainType:ExternalKaizenDesign.Build.Ship.Service.GBE-KPO-4-002-00KaizenTemplate(Office)Rev.13NorthChina/GlobalOps.March,20112DocumentTitle:KaizenTemplate(Operations)Document#:GBE-KPO-4-001-00Organization:GlobalBusinessExcellenceRevision:13DocumentOwner:AsogaTannimalayEffectiveDate:Jan07,2011APPROVALSNAMETITLEDEPTNAMEDATEGaneshSManiamSeniorDirectorGBEJan07,2011REVISIONHISTORYREVDESCRIPTIONOFCHANGEORIGINATORRELEASEDATE09DIPLSS&NWCincludedinBefore&Afterslide,NWCincludedinFinancialdashboard&VSMicon/symbolupdated.AsogaTannimalayDec11,200810SiteyokotenstatusflagcapturedinBeforeandAfterslide&VSMslideenhancedAsogaTannimalayFeb10,200911FormattedtomeetnewcorpppttemplaterequirementsAsogaTannimalayApr17,200912NWCreductionreplacedwithInventory/AR/APImprovementAsogaTannimalayMay26,200913KaizenGoalsEnhancedwithEnergyCategory(DIPLESS)AsogaTannimalayJan07,2011ThisdocumentisproprietaryandconfidentialpropertyofFlextronicsDesign.Build.Ship.Service.GBE-KPO-4-002-00KaizenTemplate(SupplyChain)Rev.13NorthChina/GlobalOps.NanjingMarch,20113TableofContentsPDCA(Plan–Do–Check–Adjust)4IndependentStudyonKaizenNeeds5KaizenTeamMembers6Goals&Objectives7TargetSheet8ValueStreamMap9StandardWorkSheet(Before)11-13SpaghettiChart(Before)14Before&AfterKaizen15-20ContentsSlide(s)ContentsSlide(s)SpaghettiChart(After)21StandardWorkSheet(After)22-23KaizenNewsPaper24-26KaizenLog(HomeworkMovingForward)27Lesson&ToolsLearned28KaizenLog(ProposalforYokoten)29AttendanceList30-31FinancialPerformanceDashboard32VSMIcon&Symbols33VSMDottingProcess&Keynotes34Design.Build.Ship.Service.GBE-KPO-4-002-00KaizenTemplate(SupplyChain)Rev.13NorthChina/GlobalOps.NanjingMarch,2011ALUDowntimechart5586416614266138778761063714413110697531111406280020040060080010001200TotalD/TWaitingMaterialD/TTotalD/T5586416614266138778761063714WaitingMaterialD/T413110697531111406280wk1-11wk2-11wk3-11wk4-11wk6-11wk7-11wk8-11wk9-11averagereasonofsupplydowntime522010810100%72%52%82%90%01020304050600%20%40%60%80%100%120%startratestart522010810rate52%72%82%90%100%L/Ttoolongsupplierdelayprepareliftbreakdownother41.Adjust4.Check2.PlanLeaninOperations-PDCATitle:ALUETEMaterialReplenishmentImprovement0-70%71%-90%91%-100%Above100%ALUETEofallissuedowntimeaverageat714mins/day,duetomaterialsupplyDownTimeaverageat80minute/day3.DoDesign.Build.Ship.Service.GBE-KPO-4-002-00KaizenTemplate(SupplyChain)Rev.13NorthChina/GlobalOps.NanjingMarch,20115IndependentStudyonKaizenNeedsNeededOutput:PotentialRiskandMetricstobeMonitored:(basedonkaizenneeds):RequiredKaizenneeds:PresentSituationandProblems:Inthepast8weeks,SMTandbackendlinewaitingmaterialtimetotalat641minuets.Dailydowntimeaverageat80minutes.Oursupermarketnotmatchthemeetsupermarketchecklist.1.Valuestreammappingtodefinethevalueandfindouttheimprovementpoint;2.Setupsupermarketandloadmaterialreplenishmentsystem;3.Standardizewaterstriderworktomaketheallstepsstandardandclearly1.No.ofitemsinsupermarketimprovefrom375to637(allofparts)2.SMTmaterialkittingtimereducefrom12hoursto4hoursAssemblymaterialkittingtimereducefrom8hoursto2hours3.Materialpickuptimefrom20sto3s4.Meetsupermarketitemsfrom2to15ALUsupplymaterialDowntimechart413110697531111406280050100150WaitingMaterialD/TWaitingMaterialD/T413110697531111406280wk1-11wk2-11wk3-11wk4-11wk6-11wk7-11wk8-11wk9-11averagDesign.Build.Ship.Service.GBE-KPO-4-002-00KaizenTemplate(SupplyChain)Rev.13NorthChina/GlobalOps.NanjingMarch,20116KaizenTeamMembersNoofShingijutsuWorkshopattended1JakeWu(Leader)ProductionManagerOperations02LinkSun(Co-leader)PEEngineering03DuanXiaofeiPEEngineering04JiDahaiMaterialShiftLeaderwarehouse05ZhangJianpingProductionLeaderOperations06XiongxiaolanMaterialShiftLeaderwarehouse07WangHongyanwaterspiderwarehouse08LiYangOPOperations09JiaDongyiOPOperations010NoofShingijutsuWorkshopattended1GraceWangBEShanghaiMalu123TeamMembersNameJobTitleFunctionalDepartmentNoNoExternalTeamMembersNameJobTitleFunctionalDepartmentDesign.Build.Ship.Service.GBE-KPO-4-002-00KaizenTemplate(SupplyChain)Rev.13NorthChina/GlobalOps.NanjingMarch,20117Note:PlsensurethatallG&Oidentifiedinthispageiscapturedunderthetargetsheet.Goals&ObjectivesObjectives1.ALUETEmaterialsupplydowntimeas0.GoalsCTQsUOMCurrentTarget%ofImprovementNo.ofitemsinsupermarketpart37563769.8%PreparationLeadTime(SMT)hour12466.6%PreparationLeadTime(Backend)hour8287.5%SMTOnLineMaterialWIPHOS12283.3%MeetSupermarketCheckListItem215100%PickuptimeforsupermarketforSMTSec.20385%PickuptimeforsupermarketforBackendSec.30390%CrewSizeCrew5260%KittingmaterialSMfromW/Hhour12191.6%NoCartonpackinginlinepart240100%Design.Build.Ship.Service.GBE-KPO-4-002-00KaizenTemplate(SupplyChain)Rev.13NorthChina/GlobalOps.NanjingMarch,20118TargetSheetNotes:•UsethisTargetSheetifprojectisnottrackingETE•PleaseensurealltheG&O’sidentifiedinPage5iscaptured.•Siteleanleaderisr