价值流分析培训.ppt
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价值流分析培训.ppt
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CI-GT-015REV.0,1,ValueStreamMapping,RecognizingtheValue-Addedstepsinyourprocesses,CI-GT-015REV.0,2,RecommendedReading,LearningtoSeebyMikeRotherandJohnShook,CI-GT-015REV.0,3,LevelsofValueStream,CI-GT-015REV.0,4,SupplyChaina.k.aValueStream,TotalValueStream,CustomertoConsumer,CI-GT-015REV.0,5,ValueStreamMapping,ValueStream-Allsteps,valueaddedandnonvalueadded,requiredtobringtheproductfromrawmaterialtocustomer.,CI-GT-015REV.0,6,WhatisaValueStreamMap?
AdetailedflowchartAbigpictureperspectiveimprovingthewhole,notjustoptimizingthepartsandmaybesub-optimizingthewholeWewillfocusonthedoor-to-doorproductioninsideaplantHelpsyouseeandunderstandtheflowofmaterialandinformation,CI-GT-015REV.0,7,CI-GT-015REV.0,8,ValueStreamMapping,CI-GT-015REV.0,9,CI-GT-015REV.0,10,BenefitsofValueStreamMapping,CI-GT-015REV.0,11,MaterialandInformationFlows,MaterialflowthemovementofmaterialthroughthefactoryInformationflowanotherflowassociatedwithproductionthattellseachprocesswhattomakeordonext,CI-GT-015REV.0,12,ValueStreamMappingSteps,ProductFamily,CurrentStateDrawing,WorkPlan,FutureStateDrawing,CI-GT-015REV.0,13,ValueStreamMappingSteps,ChooseaproductfamilyBeginbydrawingthecurrentstate(door-to-door)GatherinformationfromtheshopfloorDevelopmentofcurrentstateandfuturestateareoverlappingeffortsPrepareandbeginusinganimplementationplanRepeatwhenfuturestatebecomescurrentstate,CI-GT-015REV.0,14,ProductFamily,CI-GT-015REV.0,15,GatherData,Manufacturing,Transactional/Office,CI-GT-015REV.0,16,TypicalProcessData,CycletimeChangeovertimeProductionbatchsizesNumberofproductvariationsNumberofoperatorsPacksizeWorkingtime(minusbreaks)ScraprateOn-demandmachinetime,CI-GT-015REV.0,17,MaptheFlowofItems,usethisboxtorepresenteachprocessstepusethissymbolforcustomersandsuppliersusethissymboltorepresentasupermarket(first-in-first-out),usethissymbolforstoredinventory(knownquantities)usethissymbolforpushedinventory(arrowimpliesWIP)usethissymbolforapullsystemusethissymbolforafirst-in-first-outflowlaneusethissymbolfortransportation,FIFOmax10,CI-GT-015REV.0,18,MapFlowofInformation,usethissymbolformanualflowofinformationusethissymbolforelectronicflowofinformationusethissymboltorepresentinformationthatflows(suchasschedulesequence),usethissymbolforpullsystempapertriggerusethissymbolforapullsystemreturnablecontainertriggerusethissymbolforpullsystemtriggerataparticularquantitylevelusethissymbolforpullsystemgoseetriggerusethissymbolforpullsysteminformationstoragepoints,CI-GT-015REV.0,19,MappingTips,Alwayscollectcurrent-stateinformationwhilewalkingtheactualmaterialandinformationflowsyourself.Startwithaquickwalkalongtheentiredoor-to-doorvaluestreamthengobackandgatherdataateachprocessBeginattheshippingendandworkupstreamMeasureyourowntimesdontrelyonstandardtimes,olddatainafile,orhearsayEvenifseveralpeopleareinvolved,mapthewholevaluestreamyourselfUsebutcherpaperandmarkers,CI-GT-015REV.0,20,CurrentStateValueStreamMap,CI-GT-015REV.0,21,CurrentStateMapBytheNumbers,Startwiththecustomerplaceintheupperright-handcornerofthemapShowthecustomersrequirementsinadataboxDrawthebasicproductionprocessesindicateaprocessbyusingaprocessboxdrawmaterialflowfromlefttorightonthebottomhalfofthemapCollectdatathatwillbeimportantfordecidingwhatthefuturestatewillbedrawadataboxundereachprocessbox,CI-GT-015REV.0,22,ValueStreamMap,CI-GT-015REV.0,23,ValueStreamMap,CI-GT-015REV.0,24,CurrentStateMapBytheNumbers,NoteplacesinthematerialflowwhereinventoryaccumulatesdrawaninventorytriangletonotethelocationandamountofinventoryDrawthemovementofproducttothecustomerandnotefrequencyDrawthesupplier(s)intheupperlefthandcornerofthemapnotepacksizeanddeliveryfrequency,CI-GT-015REV.0,25,CurrentStateMapBytheNumbers,DrawtheinformationflowfromrighttoleftinthetophalfofthemapShowtheinformationflowusinganarrowthatislabeledwithnode-boxthisnodedescribestheinformationflowarrowUseseparatelinefordifferentinformationflows(e.g.,forecastsanddailyorders)Useaprocessboxtodenoteanyprocesseswithintheinformationflow,CI-GT-015REV.0,26,CurrentStateMapBytheNumbers,UseastripedarrowinthematerialflowpartofthemaptodenoteapushmovementofmaterialDrawatimelineIdentifymaterialmovementsthatarepushedbytheproducer,notpulledbythecustomerthiscanbedoneasyoufigureouthoweachprocessknowswhattomakeforitscustomerprocessandwhentomakeitDrawatimelineundertheprocessboxesandinventorytrianglestocompiletheproductionleadtime,CI-GT-015REV.0,27,ProductionLeadTime,Theleadtimecomponentforaprocessboxisthecycle-timeforaparttogothroughtheprocessLeadtimes(indays)foreachinventorytrianglearecalculatedas:
(inventoryquantity)x(takttime)/(availableworktimeperday),CI-GT-015REV.0,28,ATaktTimeReminder,Takttime=(youravailableworktimepershift)/(customerdemandpershift)Availableworkingtimeexcludesbreaks,lunch,etc.andisrecordedinsecondsCustomerdemandisrecordedinunitsorpiecesTakttimedenotestherateatwhichacustomerbuysoneproduct,CI-GT-015REV.0,29,TIMELINE,CreateatimelineacrossthebottomofyourValueStreamMapTheUppertimeshouldbeyourNon-ValueaddedtimeortheamountoftimetheproductiswaitingforprocessingTheLowertimeshouldbeValueAddedtimeortheamountofprocessingtime,CI-GT-015REV.0,30,Waste,Theelementsofproductionthataddnovaluetotheproduct.Thingstorememberaboutwaste:
Wasteisreallyasymptom,notarootcauseWastepointstoproblemsinthesystemToeliminatewaste,findandaddresstherootcause,CI-GT-015REV.0,31,ActivityProductivity,The8DeadlyWastesOverproductionProductDefectsInventoryExcessProcessTransportationExcessMotionWaitingUnder-utilizingPeople,Everybodysbusy!
Butwearestillnotdelivering!
Wheredoesallthateffortgo?
CI-GT-015REV.0,32,Howmanyoperators?
CI-GT-015REV.0,33,CI-GT-015REV.0,34,QuestionsfortheFutureState,Whatisthetakttime,basedontheavailableworkingtimeofyourdownstreamprocessesthatareclosettothecustomer?
Wherecanyouusecontinuousflowprocessing?
Whatisthepacemakerproductionprocessthatyouwillschedule?
Wherewillyouneedtointroducesupermarketpullsystemsinordertocontrolproductionofupstreamprocesses?
CI-GT-015REV.0,35,SomeDefinitions(viaanExample),Customer,OnePieceFlow,FIFOlane,Pull,Supermarket,Pacemaker,CI-GT-015REV.0,36,QuestionsfortheFutureState,Willyoubuildtoafinishedgoodsupermarketfromwhichthecustomerpulls,ordirectlytocustomerorder?
Howwillyouleveltheproductmixatthepacemakerprocess?
Whatincrementofworkwillyouconsistentlyreleaseandtakeawayatthepacemakerprocess?
Whatprocessimprovementwillbenecessaryforthevaluestreamtoflowasyourfuturestatedesignspecifies?
CI-GT-015REV.0,37,TheValueStreamPlan,AyearlyplanShowsWhatyouplantodo,step-by-stepMeasurablegoalsCheckpointswithdeadlinesandnamedpeopleaccountable,CI-GT-015REV.0,39,ConceptsinReview,_isallthesteps,valueaddedandnonvalueadded,requiredtobringtheproductfromrawmaterialtocustomer.ValueStreamMappinghelpyou_theprocess._flowisthemovementofmaterialthroughthefactory._flowtellseachprocesswhattodoormakenext.ValueStreamMappingFormulas_=inventoryqty.*takttime_=availableworktimepershiftavailableworktimedemandpershift,ValueStream,Visualize,Material,Information,Leadtime,Takttime,
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- 价值 分析 培训