实施精益供应链的10个基本要点（英文版）

©2003BusinessProcessSolutions760-940-1858www.bps.netBPSInternationalLEAN,TOC,SCM,SIXSIGMA760–940–1858www.bps.net10EssentialElementsofLeanSupplyChainJaneMarshall,MBA,CPIM,JonahNovember13,20031©2003BusinessProcessSolutions760-940-1858www.bps.netBPSInternationalLowHighCapacitiesBasicAdvancedCapabilitiesStableReactiveEfficientReactiveEfficientProactiveMaximizesProfitTraditionalSupplyChainsCollaborativeSupplyChainsSupplyChainRevolution„SupplychainshaveevolvedfromstabletoflexibleyRedistributingvaluetransformationsasmarketschangeyRequirecommunication,collaboration,andintegration2©2003BusinessProcessSolutions760-940-1858www.bps.netBPSInternational1.Definevalueasthecustomerseesit2.Determine“types”ofvalueandquantify3.Determine“takt”required(servicelevel)4.Valuestreammapyoursupplychain5.Calculateconstraints(taktflow)10LeanSupplyChainEssentials3©2003BusinessProcessSolutions760-940-1858www.bps.netBPSInternational6.Collaboratekaizenimprovementsto:7.Establishautomaticflowtriggersystems8.Evaluateandreduceleadtimevariability9.Reducequalityandperformancevariability10.Simplify,streamlineandautomateprocess10LeanSupplyChainEssentialsCont.4©2003BusinessProcessSolutions760-940-1858www.bps.netBPSInternational1)SupplyChainConceptofValue„PerceptionofVALUEthroughaproductandserviceasthecustomerseesit!„Value=Performance(Delivery,quality,cost,flexibility)Price5©2003BusinessProcessSolutions760-940-1858www.bps.netBPSInternational2)WhatdoourCustomersWant?TheyMean:OnTimeDeliveryQuality&InnovationReasonableCostsFlexibleOperationsTheySay:DependabilityReliabilityConscientiousFriendly&Helpful6©2003BusinessProcessSolutions760-940-1858www.bps.netBPSInternational3)SupplyChainDeliverables„Whatkindsofproducts(familiesorgroups)„Howoftenneeded(monthly,weekly,ordaily)„Other“services”(moreprofitableusually)„Informationavailability(ifnotnow….when?)„Resourceflexibility(helpme!)„Innovationsandcostreductions(intimacy)7©2003BusinessProcessSolutions760-940-1858www.bps.netBPSInternationalCustomerValues&SupplyChainElements„Rightcustomer„Rightproduct„Rightplace„Righttime„Rightquantity„Rightquality„RightcostCapabilitiesCapacitiesCommunication8©2003BusinessProcessSolutions760-940-1858www.bps.netBPSInternationalAreyouCapable?„Doyouhavesystemsinplaceforreliabledelivery?„Doyouhaveprocessesforconsistentquality?„Doyouhaveefficienciesthatcontaincosts?„Doyouhavepeopleinplacewhounderstandus?9©2003BusinessProcessSolutions760-940-1858www.bps.netBPSInternationalDoyouhaveCapacity?„Doyouhaveenoughortoomuchcapacity?„Doyourresourcesflexwithdemand?„Whatarecontingentresourcesforemergencies?„Istheabsorptionoffixedassetscreatingdrag?10©2003BusinessProcessSolutions760-940-1858www.bps.netBPSInternationalHowWelldoyouCommunicate?„Howeasyisitforinformationtoflow?„Howaccurateisyourinformation?„Howfrequentlyisitupdated?„Howoftendoyoucreatemanualworkarounds?11©2003BusinessProcessSolutions760-940-1858www.bps.netBPSInternational4)MapyourSupplyChainForecast&OrdersDistributionManufactureSupplyPlanningCustomerWarehouseCustomerServiceBuyersOrdersOrdersMonthlyMonthlySupplySupply12©2003BusinessProcessSolutions760-940-1858www.bps.netBPSInternationalCalculateTaktTime(DemandRates)„Takttimecalculation=availabletime/demandrate„Availabletimeis7hoursperday(420minutes)„Demandofordersis100/perday„Calculatetakttimerequiredperorder:________________13©2003BusinessProcessSolutions760-940-1858www.bps.netBPSInternational5)DetermineConstrainingAreasForecast&OrdersDistribution95Manufacture95Supply98PlanningCustomer100Warehouse100CustomerServiceBuyersOrdersOrdersMonthlyMonthlySupply100Supply9514©2003BusinessProcessSolutions760-940-1858www.bps.netBPSInternationalStep1-IdentifytheConstraintStep2–ExploittheconstrainedareaStep3–SubordinateallotherareastoitStep4–ElevatetheconstraintStep5–Startagainastheconstraintwillmove!5FocusedKaizenSteps15©2003BusinessProcessSolutions760-940-1858www.bps.netBPSInternational6)CollaborateKaizenImprovements„CollaborationyBeyondsimplecommunication–shareinformationyUnderstandingtheconstraintsandopportunitiesofyourcustomersandsuppliersyProvidetheinformationtoimprovespecificthingsyFindwaystoreducebothdoingsameactivityyFindwaystoshrinkleadtimesandlotsize16©2003BusinessProcessSolutions760-940-1858www.bps.netBPSInternational7)EstablishAutomaticTriggerSystems„Min-Max–automaticreplenishments„Weeklyreview–callorvisittomaintainservice„SharedKanbans–collaborateoncontainers„WebCams–utilizetechnologyanddialinvisuals17©2003BusinessProcessSolutions760-940-1858www.bps.netBPSInternational8)ReduceLeadtimeVariability„Variability=increasedriskofshortage„Increasedshortage=Increasedinventory„Increasedinventory=increasedwarehousespace„Increasedwarehouse=lost,damage,obsolescence„Increasedwaste=highercostallocations„Highercostallocations=uncompetitivepricing!18©2003BusinessProcessSolutions760-940-1858www.bps.netBPSInternational9)ReduceQualityandPerformanceVariability„Definequalityspecifications„Establishperformancetospecifications(sixsigma)yDefineprocessesyDetermineprocesscapability(CPK)yUsequalitytoolstodecrease