价值流程(教材经典)

5/7/20031ValueStreamMapping值流绘图Whiteboard318,400pcs/mo-12,000“L”-6,400“R”Tray=20pcs2ShiftsStateStreetAssembly1xdailyStampingS.Weld#1S.Weld#2Assembly#1Assembly#2Shipping(drawthisthenerase)Kaizen!3/14/2002ICoils5daysI4600L2400RI1100L600ROCT=62secD/R=62secC/O=0REJ=6%U/T=100%2Shifts27,600sec.Avail.OCT=40secD/R=40secC/O=0REJ=7%U/T=100%2Shifts27,600sec.Avail.ShippingStagingIII1600L850R1200L640R2700L1440RFerrousMetalsCo.500ftcoilsTues&ThursMachine1OCT=39secD/R=39secC/O=10minREJ=4%U/T=100%2Shifts27,600secAvail.OCT=1secondD/R=1secondC/O=1hourREJ=3%U/T=85%27,600sec.avail.EPE=2weeksStamp200tWeld1OCT=46secD/R=46secC/O=10minREJ=5%U/T=80%2Shifts27,600sec.Avail.1xdailySub-Assembly1Assembly1MRP18,400pcs/mo-12,000“L”-6,400“R”Tray=20pcs2ShiftsHighlandManufacturingSheetMetalHousingsCurrentState(Date)DailyShipScheduleWeeklyScheduleTT=60sec.ManchesterAvenue6-weekForecastWeeklyfaxProductionControlMRP90/60/30dayForecastsDailyOrder5days7.6days1.8days2.7days2days4.5days1sec.39sec.46sec.62sec.40sec.LeadTime=23.6daysProcessTime=188secActionRespWhenBenefit我该如何开始LEAN训练？5/7/20032VSM介绍•LEI和TSSC的源由•VSM的历史•VSM目的•介绍VSM，让学员在工作上能应用VSM•建立值流图，提供有用的信息给主办单位•发展学员鉴别值流中浪费的能力•帮助学员了解，LEAN工具如何结合，来协助我们达成工作目标•欢迎随时发问!5/7/20033第一章–值流绘图程序ValueStreamMapping5/7/20034什么是VSM？•什么是值流？值流包括了完成某一种产品或服务所必须要的所有程序步骤(加值和非加值)•什么是值流绘图？值流绘图是一种将物流和信息流可视化的方法，用以协助我们完成产品或服务5/7/20035值流改进&过程改进值流=由原材料开始到交货给顾客，所需要的步骤，包括加值和非加值的步骤ValueStream值流STAMP压字MACHINE车削ASSEMBLE装配PROCESS过程PROCESS过程PROCESS过程RawMaterial原料FinishedProduct成品Customer顾客5/7/20036值流的描绘跟随产品从结束回溯至开始的生产过程，并利用物流和信息流的图标(现况图)来描绘出可目视的图像接着绘出未来图，以显示应有的价值流动5/7/20037InformationFlowP/T1226sDistributiondailySewing3ShippingFinalAssembly2I1800pcsSuppliers.FabricWeeklyOtherBi-WeeklyProductionControlWeeklyOrders5weekForecastWeeklyOrdersWeeklyScheduleDailyShiplistFabricFabricCut3000pcs650pcsUpholstry6295pcs600pcsFrameAssyFoamAssyI2000pcs800pcs785pcsFramesMCT=60secC/O=20minOCT=150secC/O=2minOCT=501secC/O=0minOCT=395secC/O=0minOCT=60secC/O=0minOCT=60secC/O=0minIIII1000chairs/wk1ShiftIIFlowRacksF/GWarehouseTicketsMaterialFlow10d120s15d4d1.5d3dL/T33.5d210s501s395sTimelineT/T=135s5/7/20038第二章–建立现况图ValueStreamMapping5/7/20039“高地公司”生产制造的数据表实例研究的数据表在手册的附录D利用“高地公司”的数据表做实例研究检讨3/14/2002ICoils5daysI4600L2400RI1100L600ROCT=62secD/R=62secC/O=0REJ=6%U/T=100%2Shifts27,600sec.Avail.OCT=40secD/R=40secC/O=0REJ=7%U/T=100%2Shifts27,600sec.Avail.ShippingStagingIII1600L850R1200L640R2700L1440RFerrousMetalsCo.500ftcoilsTues&ThursMachine1OCT=39secD/R=39secC/O=10minREJ=4%U/T=100%2Shifts27,600secAvail.OCT=1secondD/R=1secondC/O=1hourREJ=3%U/T=85%27,600sec.avail.EPE=2weeksStamp200tWeld1OCT=46secD/R=46secC/O=10minREJ=5%U/T=80%2Shifts27,600sec.Avail.1xdailySub-Assembly1Assembly1MRP18,400pcs/mo-12,000“L”-6,400“R”Tray=20pcs2ShiftsHighlandManufacturingSheetMetalHousingsCurrentState(Date)DailyShipScheduleWeeklyScheduleTT=60sec.ManchesterAvenue6-weekForecastWeeklyfaxProductionControlMRP90/60/30dayForecastsDailyOrder5days7.6days1.8days2.7days2days4.5days1sec.39sec.46sec.62sec.40sec.LeadTime=23.6daysProcessTime=188sec5/7/200310ManchesterAvenue1xdaily18,400pcs/mo-12,000“L”-6,400“R”Tray=20pcs2shiftsTT=60sec.5/7/200311•在制程前或后有库存•在俩制程间没有实现一件流.•交接•如果是一件流交接,就不要增加另一个制程方框•如果职能之间的交接打断了流程,就要增加制程方框确定过程方框5/7/200312ManchesterAvenue1xdailyStampMachineWeldSub-AssemblyAssemblyShipping18,4000pcs/mo-12,000“L”-6,400“R”Tray=20pcs2shiftsTT=60sec.SR5/7/200313ManchesterAvenue1xdaily18,4000pcs/mo-12,000“L”-6,400“R”Tray=20pcs2shiftsTT=60sec.StampMachineWeldSub-AssemblyAssemblyShippingSR5/7/200314DataBox&ProcessBoxDefinitionsAndSymbolsTheBelowDataGetsAddedToOrAbovetheProcessBox下列数据记录于程序盒内或上方SharedResource(Sharediftheresourceisusedbyothervaluestreams)共享资源……………………………………….SRNumberOfOperators操作员人数……………………………………………………………………………………………=#NumberOfShiftsThisProcessIsRun执行此程序时的班别数………………………………………………………………..SH=#TaktTime(Shownonetimein/nearthecustomerDataBox)客户需求时间………………………………………..…………T/T=TimeNote:TheFollowingInformationGoesIntheDataBoxbelowtheProcessBox下列信息记录于程序盒下方的数据盒内OperatorCycleTime操作员周期时间…………………………………………………………………………………………OCT=TimeMachineCycleTime机器周期时间……………………………………………………………………………………………MCT=TimeDropOffRate(Howoftenafinishedpartiscompletedofftheendoftheprocess)产出率………………….…...…………..D/R=TimeProcessLeadTime(Timerequiredtocompleteabatchthroughaprocess)程序前置时间……………………...……………PLT=TimeBatchSize(Sizeofthebatchthroughaprocesswhengreaterthanonepiece)披量……………………..……...……………BATCH=PiecesProcessTimePerPiece(Processlead-timedividedbybatchsize)单件程序时间………………………………..……………PTP=TimeRejectRate(Percentofproductthatisrejectedforqualitydefects)不良率………………………………..……..….……..REJ=%Uptime(Percentofplannedtimetheprocessruns,takesoutbreakdowns&unplannedmaintenance)操作率…...……………U/T=%ChangeoverTime(TimetochangefromthelastgoodpieceofpartAtothefirstgoodpieceofpartB)换模时间…............C/O=TimeEveryPartEvery_____(Howofteneverypartnumberisrunthroughtheprocess,SetupWheel)生产循环时间....................EPE=TimePitchInterval(Howoftenthecontainerquantityiscompleted)间距时间………………………………………...……..…...PITCH=TimeProcessBoxt程序盒NOTE:Onlyplaceappropriatedatainthedatabox.Thelista