精益生产价值流图--deertower

资料下载大全ENERGIZERSCHICK-HIGHLYCONFIDENTIAL-RESTRICTEDFORINTERNALUSEONLY2WhatisLean?Leanisathatfocuseson:CreatingvaluefortheCustomerEliminatingWasteContinuousincrementalimprovement“Alloftheactions,valueornonvalueaddedthatarerequiredtobringaproductfromconcepttolaunchorfromrawmaterialordertodelivery...”From“LeanLexicon”’dwantthematerials,informationandcashtoflowsmoothly(withoutinterruption)andasquicklyaspossiblethroughthisstream.SalesOrderReceiptRMOrder&ReceiptManufacturingPackagingDistributionDelivery/Service://•“WhatisthewillingtoPayfor?”•3TypesofCustomers:Theexternalend-userorpayingcustomerThedownstreamcustomerofanyinternalupstreamprocess.Yourcompanyasthecustomerofexternalsuppliers.•Idealflow=1pieceatatime•Ratedeterminedbycustomerdemand-Takttime•Workbalancedforeachpersonormachine•Traveldistanceformaterials&peopleminimized•StandardWorkutilizedFlowwhatyoucan…Pullwhatyoucan’t…•Requiresthatallstepsintheprocessbe:Capable=RighteverytimeAvailable=AlwaysabletorunAdequate=Capacitytoavoidbottlenecks•Phase1-Identify/MapValueStreams•Phase2-Prioritizeopportunities•Phase3-UtilizeLeantoolstoeliminatewaste•Phase4-Controltheflow•Phase5-Leanmetrics•Phase6-Re-evaluateValueStreamsandbeginagain•IdentifyallformsofWastethroughoutourentireValueStreambefore:ReducingthewasteorEliminatingthewaste•Thiswillenableustoprioritizeoureffortsandfocusonthehighpotentialeventsfirst.•Overproduction•Inventory•Waiting•Transporting•Unnecessaryprocessing•Unnecessarymotion•Defects•Underutilizationofpeople•Producingmorethanwhatthecustomerreallywants.•WaystoOvercome:ReducesetuptimesSynchronizetimeandamountofprocessesCreatecompactlayoutsandvisibility•Excessinventoryrequireshandling,space,$$,people,andpaperwork.•WaystoOvercome:SynchronizeworkflowtoreduceaccumulationShortensetuptimeReduceleadtimeCellularlayoutsZeroQualityDefectsReducingallotherwastesreducesthewasteofinventory•Waitingforupstreamprocessesduetopoorlayout,unbalancedworkloadorequipmentdowntime.•WaystoOvercome:SynchronizeworkflowBalanceunevenloadsbyflexibleworkersandequipmentImplementpreventivemaintenancetoeliminatemachinedown-time•TransportationaddsNovaluetotheproduct.Ratherthanimprovethetransportation:ReduceitEliminateit.•WaystoOvercome:Establishlayoutandlocationswhichreducesoreliminatestransportation(SAP,Access,Excel)•Allunnecessary,orNon-ValueAdded,processingstepsshouldbeeliminated•WaystoOvercome:QuestionifprocessisnecessaryatallSimplifyUseStandardWorkReduceHandoffs/approvals•Motionofpeople,machines,andproductsiswaste.•WaystoOvercome:Studymotionandeliminateorreducemotionthroughimprovedlayouts.CellularManufacturingRethinkmaterialstorageJob/TaskCombinations(Correction)•Makingdefectiveproductispure(muda)waste.FocusonpreventingdefectsNotfindingandrepairingdefects•WaystoOvercome:Mistake-prooftopreventdefectsNeverPassdefectsStandardWork•Theeighthwasteisnotfullyutilizingthetimeandtalentsofpeople.•Whoarethe“real”experts?andwhatdotheyknow?