价值流程图 (3)

#1 Title 36 Pt. Arial Title Case,Bullet level 24 pt. Arial sentence case,Second level 20 pt. Arial sentence case,Third level 20 pt. Arial bold sentence case,Fourth Level 20 pt. Arial bold sentence case,64,LGB1-03-0405 VSM.ppt, 2004 Honeywell International, Inc. Confidential and Proprietary,Lean Green Belt Training,Define,Control,Improve,Analyze,Measure,LGB1-03-0405 VSM.ppt, 2004 Honeywell International, Inc. Confidential and Proprietary,#1 Title 36 Pt. Arial Title Case,Bullet level 24 pt. Arial sentence case,Second level 20 pt. Arial sentence case,Third level 20 pt. Arial bold sentence case,Fourth Level 20 pt. Arial bold sentence case,1,LGB1-03-0405 VSM.ppt, 2004 Honeywell International, Inc. Confidential and Proprietary,#1 Title 36 Pt. Arial Title Case,Bullet level 24 pt. Arial sentence case,Second level 20 pt. Arial sentence case,Third level 20 pt. Arial bold sentence case,Fourth Level 20 pt. Arial bold sentence case,*,Value Stream Mapping,价值流图,精益生产绿带培训,Improve,改进,Control,控制,Analyze,分析,Measure,测量,Define,定义,精益价值流,Value Stream,Management,Module Objectives,课程目标,Through completion of this module, the participant will,通过完成这个课程，学员将,learn to define a value stream,学习定义一个价值流,develop a line of sight to identify waste,形成识别浪费的眼光,learn how to determine the scope of VSM tool application,学习如何决定价值流图的具应用范围,know how to utilise the VSM tool,了解如何使用价值流图,A sequence of steps that must be performed in the proper sequence to create value for a customer.,可以根据适当顺序执行的，为客户创造价值的步骤。,The complete value stream includes steps required to recognize demand and plan (information) and to process (execute).,完整的价值流包括识别需求和计划（信息）以及处理（执行）所需要的步骤,The value stream includes all steps that are,value-added,and,non value-added,价值流包括所有,增值和非增值步骤。,If there is a product or a process for a customer, there is a value stream.,有为客户生产的产品或流程，就有价值流。,Many of our value streams have lead-times which are comprised of more than 90% non-value added time.,我们许多价值流的时间都包括了超过90的非增值时间。,Defining A Value Stream,确定一个价值流,Customer Value,客户价值,INFORMATION FLOW,信息流,MATERIAL FLOW,物流,Order,Entry,订单输入,Supply,Mgmt,供应管理,Production,Planning,生产计划,Sub Assy,Mfg.,分装生产,Assembly,总装,Finance,财务,Market,& Sales,市场和销售,Information,信息,The objective is to identify sources of waste at key business leverage points.,目的是找出关键业务利用点的浪费根源。,In turn, this identifies key project targets.,通常，这也可以找出关键项目的目标。,Value Stream,Thinking,价值流思路,Extended Value Stream,延伸的价值流,Multiple Facilities: Includes Suppliers & Customers),（,多个工厂：包括供应商和客户）,Process Level,流程层,Facility Level,工厂层,(door to door)（,门到门）,VSMs can be used on any process,价值流可以用于任何流程,Value Stream Levels,价值流层次,Why Value Stream Map?,为什么要价值流图？,It helps you visualize more than just the process level.,它将帮助你们更直观地了解超越流程层面的内涵。,Allows you to see the sources of,waste,.,使你们发现,浪费,的根源。,Helps target improvement projects on the right opportunities that will make a real difference to performance and flow.,帮助找出真正影响执行和流动的改进项目的适当机会。,ie. Projects that are not linked to a common strategy,即：与一般战略不相关的项目,Shows linkage - or lack thereof - between the flow of information and the flow of material.,显示信息流和材料流之间的联系性或缺乏联系性,VSM helps create a common understanding of reality and the improvement possibilities.,价值流描绘将体现共识并形成改进的可能性。,1.,Perform “Current State” extended VSM,执行“现有状态”延伸价值流图,2. Develop site-specific VSM,开发针对场所的价值流图,3. Perform a “Future State” extended VSM,执行“未来状态”的延伸价值流图,4. Develop the “Ideal State” extended VSM,形成“理想状态”延伸价值流图,Typical VSM Strategy,典型的价值流战略,The Current State, Extended,Value Stream Map,现有状态及延伸价值流图,Create the Team,创建团队,Team leader from the most downstream site,来自最下游场所的团队领导,Cross-functional: must share ownership,跨职能部门：必须共同拥有,Keep the team manageable (one per firm),保持团队的可管理性（每公司派一名）,The Extended State,Value Stream Team,延伸状态价值流团队,The,Mapping Team Leader Role,团队领导的作用,The Team Leader should,团队领导应,Form a team of all functions in the business touching the process,组织包括所有相关人员的团队,Organize a walk together to “learn to see”.,组织“学习观察”。,Identify and characterize all the steps.,识别和特征化所有步骤。,Envision a “future state” that is void of as much waste as can be accomplished within the applicable and appropriate time horizon.,预见一个在适用和适当时间内尽量没有浪费的,“,未来状态,”,。,Implement and help sustain the Future State.,执行和帮助维持未来状态。,Start the cycle again in search of the next Future State.,再次开始这个循环，寻找下一个未来状态。,Define the area/s of,analysis,确定分析区域,Consider the,Product/ process alignments,考虑产品/流程的匹配,Group of products / processes that flow through similar steps.,将类似步骤的产品/流程分组,Products / processes that utilize similar equipment in the downstream,process.,在下游流程中使用类似设备的产品/流程,This enable efficient analysis of the activity of the product,这使我们能有效地分析产品活动,Determine the VSM Scope,决定价值流图范围,Define product/process family lead time:,确定产品/流程系列的周期：,For products, obtain Bill of Material (BOM) for lead times,针对产品，获得原料单的周期时间。,For processes, determine planned/expected lead times,针对流程，决定计划/期望的时间期,and dependencies,以及依赖性,Analyze for “cold start” lead times and cost,分析“冷启动”的周期和成本,If there are multiple critical paths, start with the longest,如果有多个关键路径，从最长的关键路径开始,The VSM Scope,价值流图范围,Creating The Value Stream,最终流程,经加工,机架,核心组装,1,螺杆,6,外壳组装,1,标签,1,电缆组装,1,PCB,组装,1,铸造,定子组装,电磁线,经加工,核心,不锈钢,棒材,经加工,转子,不锈钢,棒材,经加工,外壳,铝卷存货,蓝线,(22,awg),连接器,35 天,170 天,5 天,12 天,20 天,20 天,10 天,20 天,20 天,25 天,10 天,12,天,20 天,10 天,10 天,20 天,40 天,60,days,天,电机组件材料清单,(76-4338/,A),10 天,创建价值流原料单,电机周期,0,50,100,150,200,250,电机组装,机架,核心组装,螺杆,外壳组装,标签,线缆组装,PCB,组装,天数,Identify every supplying entity, especially those on the critical path.,Start with the customer:,Creating The Value Stream,Look beyond the immediate, in-house suppliers.,找出每个工厂的“每个供应点”。,从客户开始：,工厂,流程,地区,周期,距离（哩）,运输方式,客户,XYZ,工具公司,波特兰，俄勒冈,600,货车,马达的储存,贝塔配送,丹佛，科罗拉多,5,800,货车,马达的生产和测试,贝塔制造,凤凰城，亚里桑那,45,370,货车,铸造,阿尔法铸造厂,洛杉矶，加利福尼亚,45,1820,货车,铸锭储存,ABC,仓库,圣路易斯,5,300,货车,铸锭处理,ABC,金属厂,芝加哥，伊利诺斯,120,0,货车,220,创建价值流,不要仅限于你内部的供应点。,Text,Text,Text,Text,Operation Title,Operation,Information,Customer,I,Inventory,Truck,shipment,O X O X,Idea,FIFO,Level Load,Buffer,Finished,Movement,Push Movement,Information flow,(2,way),Electronic,Information flow,Manual,information flow,Computing,system,Kanban Signal,Creating the Value Stream,The Basic VSM Icons for “painting the picture”.,文本,文本,文本,文本,操作标题,操作,信息,客户,I,存货,卡车运输,O X O X,想法,先进先出,稳定负荷,缓冲库存,成品移动,推动,信息流,（,双向）,电子,信息流,手工,信息流,计算机系统,Kanban (,看板）信号,创建价值流,“画画,”,的基本价值流图图标。,Customer,客户,Portland, Or,波 特兰，俄勒冈,2000/,wk,周,Draw Customer box,画出客户框,Location,位置,Customer demand (& variability),客户需求（和变异）,Std Dev 350,Electric Motor Assemblies,电机组件,Creating the Value Stream,创建价值流,ABC,Metal,ABC,金属,ABC,Warehouse,ABC,仓库,Alpha,Foundry,阿尔法铸造,Beta,Mfg.,贝塔制造,Beta,Distribution,贝塔配送,Chicago, Illinois,芝加哥，伊利诺斯,St. Louis, Mo,圣路易斯，,LA, Ca,洛杉矶加利福尼亚,Phx, Az,凤凰城，亚里桑那,Denver, Co,丹佛，科洛纳多,XYZ,Tool,XYZ,工具,Portland, Or,波特兰，俄勒冈,Customer,客户,2000/,wk,周,Std Dev 350,Draw a box for every facility and note location.,为每个工厂画框，标明位置.,Creating The Extended Value Stream,创造延伸价值流,80,People,ABC,Warehouse,Alpha,Foundry,Beta,Mfg,Beta,Distribution,Distribution,Die Casting,Machine & Assy,Distribution,St. Louis, Mo,LA, Ca,Phx, Az,Denver, Co,2000,tons FG,12,People,2,Shifts,Leadtime 5d,350,tons WIP,ABC,Metal,Al Ingots,500,tons FG,3,Shifts,Lead time 120d,Chicago, Illinois,Customer ppm,23000,12000,wip,212,People,2,Shifts,Leadtime 45d,2000,wip,109,People,2,Shifts,Leadtime 45d,8000,FG,10,People,1,Shifts,Leadtime 5d,13000,ppm,25000,ppm,OTD 76%,OTD 88%,XYZ,Tool,Customer,Portland, Or,2000/,wk,Create a data boxes for each facility / process step for the best data which describes the process, such as:,Lead time,Delivery performance,Quality (customer ppm),Inventory (finished goods, WIP, raw),Capacity (people, shifts),Other as applicable,Std Dev 350,Creating The Extended Value Stream,Create a data boxes for each facility / process step for the best data which describes the process, such as:,为每个工厂/过程创建数据框，框内的数据如下：,周期,交付执行,质量（客户,PPM）,库存（成品、在制品、原料）,能力（人员、班次）,其他必要的信息,创造延伸价值流,ABC,仓库,配送,圣路易斯,2000,吨成品,12,人,2,班,周期5天,阿尔法铸造,铸造,12000,在制品,212 人,2班,周期45天,25000,ppm,订单需求,76%,贝塔制造,机器和组装,2000,在制品,109 人,2 班,周期45天,13000,ppm,订单需求,88%,贝塔配送,配送,丹佛公司,8000成品,10,人,1,班,周期5天,XYZ,工具,客户,2000/ 周,标准差,350,波特兰，俄勒冈,洛杉矶，加利福尼亚,凤凰城，亚里桑那,350吨在制品,ABC,金属,铸锭,500 吨成品,3 班,周期,120,天,芝加哥，伊利诺斯,客户,ppm,23000,ABC,Metal,Al Ingots,500,tons FG,350,tons WIP,3,Shifts,80,People,ABC,Warehouse,Alpha,Foundry,Beta,Mfg,Beta,Distribution,Lead time 120d,Distribution,Die Casting,Machine & Assy,Distribution,Chicago, Illinois,St. Louis, Mo,LA, Ca,Phx, Az,Denver, Co,2000,tons FG,12,People,2,Shifts,Leadtime 5d,Customer ppm,23000,12000,wip,212,People,2,Shifts,Leadtime 45d,2000,wip,109,People,2,Shifts,Leadtime 45d,8000,FG,10,People,1,Shifts,Leadtime 5d,13000,ppm,25000,ppm,OTD 76%,OTD 88%,XYZ,Tool,Customer,Portland, Or,2000/,wk,Add the transportation links.,Capture extra transports (by air or truck) and number of expedites.,300,Miles,2x/mo,1820,Miles,1x/mo,370,Miles,1x/mo,800,Miles,2x/mo,600,Miles,1x/mo,Add the time line.,Note travel, queue, and value added segments.,5,hrs,Travel,5,hrs,5,d,30,hrs,45,d,6,hrs,45,d,5,d,12,h,Leadtime,Value,. 1,hr,1.5,hr,Std Dev 350,Creating The Value Stream,添加运输环节,记录额外的运输（空运或陆运）和速度,300英里,2x/mo,1820 英里,1x/mo,370 英里,1x/mo,800 英里,2x/mo,600 英里,1x/mo,添加时间线,注意运输、排队、增值部分,5小时,运输,5小时,5天,30小时,45天,6小时,45天,5天,12小时,周期,价值,. 1 小时,1.5小时,创建价值流,ABC,金属公司,铸锭,芝加哥，伊利诺斯,500 吨成品,350,吨在制品,3,班,80 人,周期120天,客户,PPM,23000,ABC,仓库,配送,圣路易斯,200,吨成品,12,人,2,班,周期5天,XYZ,工具,客户,2000/ 周,标准差,350,贝塔配送,配送,丹佛公司,8000成品,10,人,1,班,周期5天,贝塔制造,机器和组装,2000,在制品,109 人,2 班,周期45天,13000,ppm,订单需求,88%,阿尔法铸造,铸造,12000,在制品,212 人,2 班,周期45天,25000,ppm,订单需求,76%,洛杉矶，加利福尼亚,凤凰城，亚里桑那,Identify steps for information flows:,Creating The Value Stream,找出信息流步骤：,创建价值流,Contract,Dept,Production,Control,Order Mgmt,System,Mfg Planning,System,P.O faxed,monthly,Work,Order,LA, Ca.,Weekly,ABC,Metal,Al Ingots,500,tons FG,350,tons WIP,3,Shifts,80,People,ABC,Warehouse,Alpha,Foundry,Beta,Mfg,Beta,Distribution,Lead time 120d,Distribution,Die Casting,Machine & Assy,Distribution,Chicago, Illinois,St. Louis, Mo,LA, Ca,Phx, Az,Denver, Co,2000,tons FG,12,People,2,Shifts,Leadtime 5d,Customer ppm,23000,12000,wip,212,People,2,Shifts,Leadtime 45d,2000,wip,109,People,2,Shifts,Leadtime 45d,8000,FG,10,People,1,Shifts,Leadtime 5d,13000,ppm,25000,ppm,OTD 76%,OTD 88%,Map the flow of information flow, starting with the customer order.,300,Miles,2x/mo,1820,Miles,1x/mo,370,Miles,1x/mo,800,Miles,2x/mo,600,Miles,1x/mo,Production,Control,Daily,Production,Control,Purchasing,Dept,Weekly,Phx, Az,Phx, Az,Denver, Co.,XYZ,Tool,Customer,Portland, Or,2000/,wk,Faxed P.O.,MRP,&,email,Customer,Support,5,hrs,5,d,30,hrs,45,d,6,hrs,45,d,5,d,12,h,5,hrs,.1,hr,1.5,hr,Std Dev 350,Sales,Dept,St. Louis, Mo.,Production,Control,Production,Control,St. Louis, Mo.,Chicago, Il,Factory Order,System,Faxed P.O.,Monthly,Bi-weekly,Creating The Value Stream,承包部,生产控制部,订单管理系统,管理规划系统,每月传真,工作指令,加利福尼,亚洛杉机,每周,ABC,金属公司,铸锭,500 吨,FG,350,吨在制品,3,班,80人,ABC,仓库,阿尔法铸造,贝塔制造,贝塔配送,周期120天,配送,铸造,机器和组装,配送,芝加哥，伊利诺斯,圣路易斯,洛杉矶，加利福尼亚,凤凰城，亚里桑那,丹佛公司,200,吨成品,12,人,2,班,周期5天,客户,PPM,23000,12000,在制品,212 人,2 班,周期45天,2000,在制品,109 人,2 班,周期45天,8000 成品,10,人,1,班,周期5天,13000,ppm,25000,ppm,订单需求,76%,订单需求,88%,从客户订单开始，描绘信息流。,300 英里,2x/mo,1820 英里,1x/mo,370 英里,1x/mo,800 英里,2x/mo,600 英里,1x/mo,生产控制部,每日,生产控制部,采购部,每周,凤凰城，,亚里桑那,凤凰城，,亚里桑那,丹佛公司,XYZ,工具,客户,波特兰，俄亥俄,2000/周,传真订单,MRP,电子邮件,客户支持部,5小时,5天,30小时,45天,6小时,45天,5天,1小时,5小时,.1 小时,1.5小时,标准差 350,销售部,圣路易斯,产品控制部,产品控制部,圣路易斯,芝加哥,工厂订单系统,传真订单,每月,每两周,创建价值流,Total Lead Time,总周期,VA %,增值时间比例,Inventory Turns,库存周转率,Delivery Performance (OTTR),及时交货率,Quality (Customer PPM),质量(客户,PPM）,Product Travel Distance,产品移动距离,Current State Summary,现状小结,220,days,天,.0001%, 6,89%,13000 PPM,3980 miles,英哩,Source: “Seeing The Whole” by James Womack and Daniel Jones, 2002,Example 2: Current State Extended VSM,例2：现有状态延伸价值流图,Launch Site-Specific VSM,建立特定场所的价值流图,Identify the firms that are contributing value:,识别创造价值的公司：,If unable to launch simultaneously, start with the business closest to the customer along the value stream,如果无法同时进行，可以从价值流上最接近客户的业务开始,Create a committed team,创建一个有承诺的团队,Team leader: the extended VSM participant,团队领导：延伸价值流图参与人,Team members must be process owners,团队成员必须是流程所有者,Site leadership participation is critical,工厂领导层的参与非常关键,Train the team in lean basics,将精益生产基础知识传授给团队,Starting Site-Specific VSM,开始特定场所的价值流图,Begin current state map activity by walking the process:,Site-Specific VSM,通过回顾流程启动现有状态的描绘活动,步骤,描述,增值时间,距离,潜在失败模式,天,小时,分钟,英尺,阿尔法铸造,10,卸载的铸锭,20,20,11,收到铸锭、审核书面材料,2,12,将铸锭搬如仓库,4,80,13,储存铸锭,10,14,发放工作订单,5,15,计算和发放铸锭,20,16,移入铸造平台区,3,35,17,平台（变化）,4,多余变化,18,移入铸造压床,2,25,19,装入融解炉,1,8,20,循环压铸生产部件,1,停机时间（核心设备）,21,检验第一个部件,5,22,部件装入集装箱,1,4,23,货车将部件运往剪裁区,2,80,24,将集装箱部件/移入剪裁压床,1,40,25,将剪裁部件/装入集装箱,总时间,特定场所的价值流图,Create the “current state” value stream map using the same icons and format,使用相同的图标和格式，创建当前状态的价值流图,Start with the customer order and follow the information channels,从客户订单开始，跟随信息通道,Integrate the hardware flow,整合硬件流,Site-Specific VSM,特定场所的价值流图,Beta Mfg,8000,pcs/month (avg),Std Dev 3500,MRP,(,Oracle),P.O. Faxed monthly,Contract,administrator,Weekly calls,-,prioirity changes,-,inventory availability,Order entry,Planner,Tool Crib,P.O. faxed,monthly,Telephone Call,Traveler &,setup card,Production Order,Gages,Weekly regen,ABC Metals,Stage,Place next to,machine,DOCK,Receive,Ingots,Receipt Transaction,1 - 2,shipments bi-weekly,20,000,lbs. ($12,800),10,skid increments,2000,lb per skid,I,15,skids,2,days,10,days,4,hrs,Cast,Setup, auto,run, place in,crate,Stage,Wait for,trucker,op10-11,Tool room,I,Clean,Die,114,855,pcs,8,Die Cast Machines,Cycle time: 30 secs,Uptime: Not known,Changeover 2-6 hrs,2,shifts: 8 people,2,days,30,secs,2,hrs,6,weeks,2-6,hr,setups,Unplanned,downtime,Broken,Core,Pins!,4-6,wk,tool,repair,Tool,Cleaning,1-2,wks,Current State Summary,On time delivery 76%,Lead time 45 days,Customer ppm 25000,Value added% 1%,Inventory turns 6,Line failures:,porosity,Trim,Load, run,unload press,Finish,Load, run,unload wheel,op20,Move transaction/Backflush,Production order/priority,Production order/priority,I,7650,pcs,Machines: 5,Cycle time: 10 sec,Uptime: TBD,Shifts: 1,Machines: 3,Cycle Time: 1-2 min,Uptime: TDB,Shifts 2: (2 people),Changeover: TBD,Changeover 20 min,Shipping,Package &,ship,op30,2,days,10,secs,2,days,1,day,2,min,2,days,“Alpha Foundry” Current State VSM,8 die cast machines (7 Aluminum, 1 Zinc,Approximately 90 part numbers,8,台铸造机（,7,个铝、1个 锌）,约90个部件,贝塔制造公司,8000,件,/,月（平均）,标准差,3500,手工,订单处理,每月传真订单,合同管理员,每周拜访,首要变化,库存可用性,订单录入,计划员,工具信息库,订单每月传真,电话,移动和设置卡,生产指令度量,每月重建,ABC,金属公司,阶段,放在机器边,卸货平台,收到铸锭,收货交易,两周发货一次,20,000 lbs,磅,. ($12,800),10,累计制动,每次制动力为,2000,磅,I,15 刹车,2 天,10 天,4 小时,铸造,设置、自动,运行、放置,阶段,等待货车,操作次数10-11,工具间,I,清洗模具,114,855,PCs,台铸造机器,周期: 30 秒,开机时间: 未知,切换时间为,2-6,小时,2 班: 8 人,2 天,30 秒,2 小时,6 周,26,小时设置,未预期停机,损坏的,核心栓,46,周,工具修理,工具清洁,12周,现有状态总结,按时交货 76%,周期 45 天,客户计划 25000,增值% 1%,库存周转 6,生产线故障,:,多孔,剪裁,装货运行、卸货,完成,装货、运行、,卸货,操作次数20,移动交易,生产订单,/,顺序,生产指令/优先,I,7650 件,机器: 5,周期时间: 10 秒,开机时间: 待定,班: 1,机器: 3,周期时间: 1-2 分,开机时间: 待定,班2: (2 人),切换时间为:,TBD,切换时间为20 分钟,发货,包装起运,操作次数,30,2 天,10 秒,2 天,1 天,2 分,2 天,阿尔法铸造现状价值流图,Overproduction:,producing 6-8 weeks of castings prior to downstream consumption.,Defects,: porosity defects detected at customer site.,Unnecessary Inventory,: producing more than what was ordered was “justified” through the avoidance of changeover time.,Unnecessary processing:,flash removal.,Unnecessary transportation:,significant movement of material between process steps.,Waiting:,operators waiting for tool die repair.,Unnecessary motion:,operators walking around area looking for tools, material, gauges, etc.,Identifying Waste,过度生产：,在下游消费前生产68个月的铸件,缺陷：,客户发现多孔的缺陷,不必要的库存：,生产量大于定购量（即：避免产品切换）,不必要的处理,：,将闪光框移开,不必要的运输：,原料在流程步骤之间移动,等候：,操作员等待模具的修理,不必要的动作：,操作员四处寻找工具、材料、测量仪器等。,识别浪费,Future state designs incorporates process steps that:,未来状态设计包括以下步骤,Adds value,增值: 1). 2) . 3).,Is available: not constrained by downtime or capacity,可用：不受停机或能力限制,Is capable,:,can reliably repeat the process,有能力：可以可靠地重复流程,And are linked by:,由以下连接：,Flow: with little or no queue, regulated by takt time,流动：很少或没有排队，由节拍时间控制,Pull: produce at the pull of the downstream process step,拉动：产品由下游流程步骤拉动,Level demand: minimal variation in information ：,均衡的,需求：最少的信息变化,Elements Of The Future State Design,未来状态设计的要素,Value-added steps (3) = 1%,增值步骤（3）=,1%,Process availability: excessive downtime (core pins, changeover),流程可用性：过多的停机时间（销钉、切换）,Capability: customer reports of excessive porosity,能力：客户报告有过多的气孔,Flow: large batches due to excessive tool repair time, changeover,time, and separate finishing processes,流动：由于过多的工具修理,时间、切换和独立的精加工流程导致较大批量,Pull systems: none. MRP push,拉动系统：没有。,MRP,推动,Level demand: excessive variability in demand,均衡需求：需求变化过多,Alpha Foundry Analysis,阿尔法铸造公司分析,Future State focus:,未来状态关注：,Stabilize the process to eliminate “pure waste”,稳定流程，消除“纯粹的浪费”,excessive core pin replacements, die repair time, changeover time, and porosity,过多的销钉更换，模具修理时间，变化时间和气孔。,2) Link all process steps to minimize non-value added steps,将所有流程步骤连接起来，最大程度减少非增值步骤,create flow,创造流动,pull replenishment,拉动式补货,level demand,均衡需求,Creating the Future State,创建未来状态,Removing waste from the process:,Step,Description,VA Time,Distance,Action,Days,Hrs,Min,Feet,Alpha Foundry:,10,Unload ingots,20,20,11,Receive ingots, verify paperwork,Establish VMI program with,12,Move ingots to storage,ABC metal,13,Store ingots,14,Release work order,5,15,Count and release ingots,16,Move to Die Cast staging area,17,Stage (changeover),1,Setup reduction,18,Move to Die Cast press,2,25,19,Load into melting pot,1,8,20,Cycle press to produce parts,1,Core pin management program,21,Inspect 1st part,5,22,Load parts into container,1,4,23,Call trucker and move parts to trim area,2,80,Use small moveable box,24,Move container/parts to trim press machine,1,20,Move trim presses to die cast,25,Trim parts/load into container,Total Time,The Future VSM: “Alpha Foundry”,将浪费从流程中清除：,步骤,描述,增值时间,距离,行动,日,小时,分钟,英尺,阿尔法铸造：,10,卸载的铸锭,20,20,11,收到铸锭、审核书面材料,与,ABC,金属一起建立,VMI,计划,12,将铸锭搬如仓库,13,储存铸锭,14,发放工作订单,5,15,计算和发放铸锭,16,移入铸造平台区,17,平台（变化）,1,减少设置,18,移入铸造压床,2,25,19,装入融解炉,1,8,20,循环压铸生产部件,1,核心设备管理计划,21,检验第一个部件,5,22,部件装入集装箱,1,4,23,货车将部件运往剪裁区,2,80,使用小的活动盒,24,将集装箱部件/移入剪裁压床,1,20,将剪裁压床移入铸造,25,将剪裁部件/装入集装箱,总时间,未来价值流图：阿尔法铸造,2,min,DOCK,VMI,Ingots,2 wks supply,ABC Metals,Beta Mfg,MRP,(,Oracle),Trim,Finish,op20,Shipping,op30,Load, run,unload press,Load, run,unload wheel,Machines: 5,Cycle time: 10 sec,Uptime: TBD,Shifts: 1,Machines: 3,Cycle Time: 1-2 min,Uptime: TDB,Shifts 2: (2 people),Changeover: TBD,Changeover 20 min,ship,1,day,10,secs,1,day,10,days,2,min,1,day,Finished Goods,2 weeks supply,Tool room,Clean,2,wk,Stage,Place next to,machine,2,hrs,Cast,Setup, auto,run, place in,box,Die,8,Die Cast Machines,Cycle time: 30 secs,Uptime: Not know