价值流分析培训

CI-GT-015REV.01ValueStreamMappingRecognizingtheValue-AddedstepsinyourprocessesCI-GT-015REV.02RecommendedReadingLearningtoSeebyMikeRotherandJohnShookCI-GT-015REV.03LevelsofValueStreamCI-GT-015REV.04SupplyChaina.k.aValueStreamSuppliersXxxBranch(es)CustomertoConsumerTodayCI-GT-015REV.05ValueStreamMappingValueStream-Allsteps,valueaddedandnonvalueadded,requiredtobringtheproductfromrawmaterialtocustomer.CI-GT-015REV.06WhatisaValueStreamMap?•Adetailedflowchart•Abigpictureperspective–improvingthewhole,notjustoptimizingthepartsandmaybesub-optimizingthewhole•Wewillfocusonthedoor-to-doorproductioninsideaplant•HelpsyouseeandunderstandtheflowofmaterialandinformationCI-GT-015REV.07CI-GT-015REV.08ValueStreamMappingCI-GT-015REV.09CI-GT-015REV.010BenefitsofValueStreamMappingCI-GT-015REV.011MaterialandInformationFlows•Materialflowthemovementofmaterialthroughthefactory•InformationflowanotherflowassociatedwithproductionthattellseachprocesswhattomakeordonextCI-GT-015REV.012ValueStreamMappingStepsProductFamilyCurrentStateDrawingWorkPlanFutureStateDrawingCI-GT-015REV.013ValueStreamMappingSteps•Chooseaproductfamily•Beginbydrawingthecurrentstate(door-to-door)–Gatherinformationfromtheshopfloor•Developmentofcurrentstateandfuturestateareoverlappingefforts•Prepareandbeginusinganimplementationplan•RepeatwhenfuturestatebecomescurrentstateCI-GT-015REV.014ProductFamilyCI-GT-015REV.015GatherDataTrigger:Done:ManualCycleTime:AutoCycleTime:TaktTime:NumberofPeople:WIPPieces:C/OTime:DistanceItemTravels:%Rework:Top3Defects:1.2.3.Trigger:Done:CycleTime:TaktTime:NumberofPeople:NumberofApprovals:ItemsinInbox:%Rework:Top3ReworkIssues:1.2.3.ManufacturingTransactional/OfficeCI-GT-015REV.016TypicalProcessData•Cycletime•Changeovertime•Productionbatchsizes•Numberofproductvariations•Numberofoperators•Packsize•Workingtime(minusbreaks)•Scraprate•On-demandmachinetimeCI-GT-015REV.017MaptheFlowofItemsusethisboxtorepresenteachprocessstepusethissymbolforcustomersandsuppliersusethissymboltorepresentasupermarket(first-in-first-out)PROCESSnotesanddetailsEXTERNALPLACESusethissymbolforstoredinventory(knownquantities)usethissymbolforpushedinventory(arrowimpliesWIP)usethissymbolforapullsystemusethissymbolforafirst-in-first-outflowlaneusethissymbolfortransportationIFIFOmax10CI-GT-015REV.018MapFlowofInformationusethissymbolformanualflowofinformationusethissymbolforelectronicflowofinformationusethissymboltorepresentinformationthatflows(suchasschedulesequence)usethissymbolforpullsystempapertriggerusethissymbolforapullsystemreturnablecontainertriggerusethissymbolforpullsystemtriggerataparticularquantitylevelusethissymbolforpullsystemgoseetriggerusethissymbolforpullsysteminformationstoragepointsinformationCI-GT-015REV.019MappingTips•Alwayscollectcurrent-stateinformationwhilewalkingtheactualmaterialandinformationflowsyourself.•Startwithaquickwalkalongtheentiredoor-to-doorvaluestream–thengobackandgatherdataateachprocess•Beginattheshippingendandworkupstream•Measureyourowntimes–don’trelyonstandardtimes,olddatainafile,orhearsay•Evenifseveralpeopleareinvolved,mapthewholevaluestreamyourself•UsebutcherpaperandmarkersCI-GT-015REV.020CurrentStateValueStreamMapCI-GT-015REV.021CurrentStateMap–BytheNumbers1.Startwiththecustomer–placeintheupperright-handcornerofthemap2.Showthecustomer’srequirementsinadatabox3.Drawthebasicproductionprocesses–indicateaprocessbyusingaprocessbox–drawmaterialflowfromlefttorightonthebottomhalfofthemap4.Collectdatathatwillbeimportantfordecidingwhatthefuturestatewillbe–drawadataboxundereachprocessboxCI-GT-015REV.022ValueStreamMapCI-GT-015REV.023ValueStreamMapCI-GT-015REV.024CurrentStateMap–BytheNumbers5.Noteplacesinthematerialflowwhereinventoryaccumulates–drawaninventorytriangletonotethelocationandamountofinventory6.Drawthemovementofproducttothecustomerandnotefrequency7.Drawthesupplier(s)intheupperlefthandcornerofthemap–notepacksizeanddeliveryfrequencyCI-GT-015REV.025CurrentStateMap–BytheNumbers8.Drawtheinformationflowfromrighttoleftinthetophalfofthemap9.Showtheinformationflowusinganarrowthatislabeledwithnode-box–thisnodedescribestheinformationflowarrow10.Useseparatelinefordifferentinformationflows(e.g.,forecastsanddailyorders)11.UseaprocessboxtodenoteanyprocesseswithintheinformationflowCI-GT-015REV.026CurrentStateMap–BytheNumbers12.Useastripedarrowinthematerialflowpartofthemaptodenoteapushmovementofmaterial13.DrawatimelineIdentifymaterialmovementsthatarepushedbytheproducer,notpulledbythecustomer–thiscanbedoneasyoufigureouthoweachprocessknowswhattomakeforitscustomerprocessandwhentomakeit14.DrawatimelineundertheprocessboxesandinventorytrianglestocompiletheproductionleadtimeCI-GT-015REV.027ProductionLeadTime•Theleadtimecomponentforaprocessboxisthecycle-timeforaparttogothroughtheprocess•Leadtimes(indays)foreachinventorytrianglearecalculatedas:(inventoryquantity)x(takttime)/(availableworktimeperday)CI-GT-015REV.028ATaktTimeReminder•Takttime=(youravailableworktimepershift)/(customerdemandpershift)•Availableworkingtimeexcludesbreaks,lunch,etc.andisrecordedinseconds•Cu