如何绘制VSM-价值流分析图(68页)

Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,11/7/2009,#,Jerry Liu,单击此处编辑母版标题样式,单击此处编辑母版文本样式,第二级,第三级,第四级,第五级,单击此处编辑母版标题样式,单击此处编辑母版文本样式,第二级,第三级,第四级,第五级,*,单击此处编辑母版标题样式,单击此处编辑母版文本样式,第二级,第三级,第四级,第五级,*,*,单击此处编辑母版标题样式,单击此处编辑母版文本样式,第二级,第三级,第四级,第五级,VSM PRSENTATION CHTRAD REV3,May 7, 2003,*,of 122,Value Stream Mapping,VSM,的目的,Value Stream Mapping (VSM)是,价值流程图，它可以指出在进行生产或服务时， 还需要那些,Lean工具来辅助，以及改善工作的优先级。每一项VSM活动都会产生改善行动计划(Kaizen Action Plan)，它将根本地对质量、交期、,库存、成本、生产率等产生大幅度的改进。,什么是,VSM,价值流包括了完成某一种产品或服务由原材料开始到交货给顾客所需要的必须的所有制程步骤，它包括加值过程和非价值过程，由物流、信息流、工艺流程和数据信息组成。,VSM,能做到的和不能做到的,VSM,能够指出价值流中的浪费，并确认出消除浪费的改善活动,。,VSM,本身，并不能改善价值流。,VSM,不能取代使我们改进的改善活动。,VSM,不能取代改进过程的领导力。,Product Family,产品族,Current-state map,现况图,Future-state map,未来图,Implementation,实现,Kaizen Action plan,改善行动计划,价值流绘图的,过程,步骤,什么是产品族,根据战略部署或者顾客的需求，来找出需要改进的产品族。,同一族具有相似的制程、设备和顺序。,产品族不是产品使用者或经销商所认为的产品类别。,不具有相同制程就不是同一个产品族。,PQPR,产品数量生产制程表,一个产品族,现况图,现况图是跟随一个产品从结束回溯至开始的生产制程，并利用物流和信息流的图标来描绘出可目视的价值流图。,The Below Data Gets Added To Or Above the,Process Box,下列数据记录于制程盒内或上方,Shared Resource (Shared if the resource is used by other value streams),共享资源,.,SR,Number Of Operators,操作员人数,=,#,Number Of Shifts This Process Is Run,执行此,制程,的班,次,数,.,SH,=,#,Takt Time ( Shown one time in/near the customer Data Box),客户需求时间,T/T,=,Time,Note: The Following Information Goes In the,Data Box,below the Process Box,下列信息记录于制程盒下方的数据盒内,Operator Cycle Time,操作员周期时间,OCT,=,Time,Machine Cycle Time,机器周期时间,MCT,=,Time,Drop Off Rate (How often a finished part is completed off the end of the process),产出率,.,D/R,=,Time,Process Lead Time (Time required to complete a batch through a process),制程,前置时间,PLT,=,Time,Batch Size (Size of the batch through a process when greater than one piece),披量,. ,BATCH,=,Pieces,Process Time Per Piece (Process lead-time divided by batch size),单件,制程,时间,PTP,=,Time,Reject Rate (Percent of product that is rejected for quality defects),不良率, .,REJ,=,%,Uptime (Percent of planned time the process runs, takes out breakdowns & unplanned maintenance),可,操作,时,率,U/T,=,%,Changeover Time (Time to change from the last good piece of part A to the first good piece of part B),换模时间,C/O,=,Time,Every Part Every_ (How often every part number is run through the process, Setup Wheel),生产循环时间,EPE,=,Time,Pitch Interval (How often the container quantity is completed),间距时间,.,PITCH,=,Time,Process Box,t,制程盒,NOTE:Only place appropriate data in the data box.,The list above may not be totally inclusive.,Data Box,资料盒,数据盒只记录实际需要的数据，不一定要记录上面的全部信息,数据盒和制程方框的定义及符号,精益价值流的观念,第一个观念：遵循值流来重新架构组织,价值流的改造是一件大工程，它是各个职能的成员组成的一个团队，并选出一个合适的,Leader,。为了有效支持改造工作，管理方面的和实质的资源必须步调一致，遵循价值流团队所设定的目标，各成员定期向负责人汇报进度。,精益价值流的观念,第二个观念：计算出客户需求时间,(Takt time),客户需求时间,(Takt time),是指为了满足客户需求，产品需要以多快的速度产出，它是把每天可用的工作时间除以客户每天的需求量，所得到的计算结果。这个结果表示值流产出一件成品所应该采用的生产步伐，它与销售的步伐一致，因此不会有生产过剩的现象。客户需求时间记录在值流图的客户数据盒,(data box),内,。,精益价值流的观念,第三个观念：尽可能发展一件流,其意义为在历经的多个步骤中，一次只生产一件，让每个步骤之间不会产生停滞。,一件流的表示方法就是在执行一件流的地方划一个程序盒,(process box),。当不同的程序以一件流连接时，这些程序应该合并为一个程序盒。,One,per,Day,Dont Produce 7 units once per week,when the customer wants 1 per day.,当顾客,一天,需要一部时，不要一星期一次给七部,1 Day,1 Day,Takt Time = 1 Day,客户需求时间,=,一天,Production should be pulled along at Takt time.,Do not allow room or capability for batching.,要照着客户需求时间来拉引，不要因为空间和产能足够而推挤,精益价值流的观念,第四个观念：缩短换模时间和小批量运行,缩短换模时间可以移除小批量运行的其中一个主要障碍。如果上游程序以小批量来运行，一旦下游的需求有变动时，可以更快速地反应。应该持续地努力降低为了生产多样产品所耗费的时间，例如：换模时间。生产多样产品所耗费的时间以生产循环时间,(EPE),记录于数据盒。,精益价值流的观念,第五个观念：在无法执行一件流的地方使用看板拉引系统,看板拉引系统可以有效地将精益价值流,(lean value stream),中不连贯的程序结合起来，可以用在一件流中断的地方，避免超量生产。,先进先出,FIFO (“first in, first out”),是另外一种程序之间移动料件的方法。,精益价值流的观念,第六个观念：只对价值流中的一个制程发出生产排程,价值流中的信息流,(information flow),可以简化，在精益价值流中接受生产排程命令的程序称为引导程序,(pacemaker process),。引导点必须排除值流中其他程序的产能限制，来安排全部上游程序的生产步调。选定引导程序是非常重要的。,精益价值流的观念,第七个观念：引导点的生产数量及种类平稳化,当高批量成为常态性的生产模式时，会产生过多的浪费，在大量库存品的背后将隐藏严重的问题。,批量处理也就表示上游的材料也是以批量来投入，这样会增加在制品的库存量，也会扩大生产排程的错误。,利用负荷平稳化,(Load leveling),可以很大限度的解决问题，平准盒,(Heijunka box),可以协助我们将混杂产品及生产数量平稳化。,平准盒,(Heijunka box),Kanban are responded to from left to right at pitch increment,看板由左至右，依序置于相对应的间距时间格子内,One row,per,Product,type,一种产品一排,8:00,8:10,8:20,8:30,8:40,8:50,9:00,9:10,Type,A,Type,B,Type,C,A,One column per pitch.,一列为一间距时间,Here pitch = 10 min.,B,C,A,B,C,A,B,精益价值流的观念,第八个观念：主要绩效指标,(KPI),测量价值流中重要项目的效能是否已经转变为精益价值流,(lean value stream),。经常审视整个值流中的安全,(S),、质量,(Q),、交期,(D),、库存,(I),、成本,(C),以及生产率,(P),等，以确认主要绩效指标的进度目标是否有达到和应该注意改善的地方。,精益价值流的观念,第九个观念：持续改善的领导力,无论价值流变成多么精益，总是还有改善的空间。每当除去一种浪费，另一种浪费就很容易浮现出来，所有价值流的成员必须持续地消除浪费，除非这些程序已标准化和被有效地维持，否则几个月努力消除的浪费又会逐渐回复并侵蚀我们的成果。,I,Coils,5 days,I,4600,L,2400 R,I,1100,L,600 R,OCT = 62 sec,D/R = 62 sec,C/O = 0,REJ = 6%,U/T =100%,2 Shifts,27, 600 sec. Avail.,OCT = 40 sec,D/R = 40 sec,C/O = 0,REJ = 7%,U/T = 100%,2 Shifts,27,600 sec. Avail.,Shipping,Staging,I,I,I,1600,L,850 R,1200,L,640 R,2700,L,1440 R,FerrousMetals Co.,500,ft coils,Tues &,Thurs,Machine,1,OCT= 39 sec,D/R = 39 sec,C/O = 10 min,REJ = 4%,U/T= 100%,2 Shifts,27, 600 sec Avail.,MCT = 1 second,C/O = 1 hour,REJ = 3%,U/T = 85%,27,600 sec. avail.,EPE = 2 weeks,Stamp,200,t,Weld,1,OCT = 46 sec,D/R = 46 sec,C/O = 10 min,REJ = 5%,U/T = 80%,2 Shifts,27,600 sec. Avail.,1,x,daily,Sub-Assembly,1,Assembly,1,MRP,18,400,pcs/mo,-12,000 “L”,-6,400 “R”,Tray = 20 pcs,2 Shifts,Highland Manufacturing,Sheet Metal Housings,Current State,(Date),Daily ShipSchedule,Weekly Schedule,TT = 60 sec.,ManchesterAvenue,6-,weekForecast,Weeklyfax,ProductionControl,MRP,90/60/30,dayForecasts,DailyOrder,5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days,1 sec. 39 sec. 46 sec. 62 sec. 40 sec.,Lead Time=,23.6 days,Process Time= 188 sec,What is Takt Time?,客户需求时间是多少？,I,Coils,5 days,I,4600,L,2400 R,I,1100,L,600 R,OCT = 62 sec,D/R = 62 sec,C/O = 0,REJ = 6%,U/T =100%,2 Shifts,27, 600 sec. Avail.,OCT = 40 sec,D/R = 40 sec,C/O = 0,REJ = 7%,U/T = 100%,2 Shifts,27,600 sec. Avail.,Shipping,Staging,I,I,I,1600,L,850 R,1200,L,640 R,2700,L,1440 R,FerrousMetals Co.,500,ft coils,Tues &,Thurs,Machine,1,OCT= 39 sec,D/R = 39 sec,C/O = 10 min,REJ = 4%,U/T= 100%,2 Shifts,27, 600 sec Avail.,MCT = 1 second,C/O = 1 hour,REJ = 3%,U/T = 85%,27,600 sec. avail.,EPE = 2 weeks,Stamp,200,t,Weld,1,OCT = 46 sec,D/R = 46 sec,C/O = 10 min,REJ = 5%,U/T = 80%,2 Shifts,27,600 sec. Avail.,1,x,daily,Sub-Assembly,1,Assembly,1,MRP,18,400,pcs/mo,-12,000 “L”,-6,400 “R”,Tray = 20 pcs,2 Shifts,Highland Manufacturing,Sheet Metal Housings,Current State,(Date),Daily ShipSchedule,Weekly Schedule,TT = 60 sec.,ManchesterAvenue,6-,weekForecast,Weeklyfax,ProductionControl,MRP,90/60/30,dayForecasts,DailyOrder,5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days,1 sec. 39 sec. 46 sec. 62 sec. 40 sec.,Lead Time=,23.6 days,Process Time= 188 sec,2.,Will you build to a finished goods supermarket or directly to customer order?,价值流是到成品超市为止，还是到顾客订单？,0,s,39,s,46,s,62,s,40,s,Takt time,60 seconds,Stamp Machine Weld Sub-assy Assy,(auto-feed),3.,Where can one-piece flow be implemented? The stamping press?,那里,可以,执行一件流？在冲压制程,？,No why not?,不行,-,为何不行？,I,Coils,5 days,I,4600,L,2400 R,I,1100,L,600 R,OCT = 62 sec,D/R = 62 sec,C/O = 0,REJ = 6%,U/T =100%,2 Shifts,27, 600 sec. Avail.,OCT = 40 sec,D/R = 40 sec,C/O = 0,REJ = 7%,U/T = 100%,2 Shifts,27,600 sec. Avail.,Shipping,Staging,I,I,I,1600,L,850 R,1200,L,640 R,2700,L,1440 R,FerrousMetals Co.,500,ft coils,Tues &,Thurs,Machine,1,OCT= 39 sec,D/R = 39 sec,C/O = 10 min,REJ = 4%,U/T= 100%,2 Shifts,27, 600 sec Avail.,MCT = 1 second,C/O = 1 hour,REJ = 3%,U/T = 85%,27,600 sec. avail.,EPE = 2 weeks,Stamp,200,t,Weld,1,OCT = 46 sec,D/R = 46 sec,C/O = 10 min,REJ = 5%,U/T = 80%,2 Shifts,27,600 sec. Avail.,1,x,daily,Sub-Assembly,1,Assembly,1,MRP,18,400,pcs/mo,-12,000 “L”,-6,400 “R”,Tray = 20 pcs,2 Shifts,Highland Manufacturing,Sheet Metal Housings,Current State,(Date),Daily ShipSchedule,Weekly Schedule,TT = 60 sec.,ManchesterAvenue,6-,weekForecast,Weeklyfax,ProductionControl,MRP,90/60/30,dayForecasts,DailyOrder,5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days,1 sec. 39 sec. 46 sec. 62 sec. 40 sec.,Lead Time=,23.6 days,Process Time= 188 sec,4.,What is the pacemaker process?,引导制程在那里？,I,Coils,5 days,I,4600,L,2400 R,I,1100,L,600 R,OCT = 62 sec,D/R = 62 sec,C/O = 0,REJ = 6%,U/T =100%,2 Shifts,27, 600 sec. Avail.,OCT = 40 sec,D/R = 40 sec,C/O = 0,REJ = 7%,U/T = 100%,2 Shifts,27,600 sec. Avail.,Shipping,Staging,I,I,I,1600,L,850 R,1200,L,640 R,2700,L,1440 R,FerrousMetals Co.,500,ft coils,Tues &,Thurs,Machine,1,OCT= 39 sec,D/R = 39 sec,C/O = 10 min,REJ = 4%,U/T= 100%,2 Shifts,27, 600 sec Avail.,MCT = 1 second,C/O = 1 hour,REJ = 3%,U/T = 85%,27,600 sec. avail.,EPE = 2 weeks,Stamp,200,t,Weld,1,OCT = 46 sec,D/R = 46 sec,C/O = 10 min,REJ = 5%,U/T = 80%,2 Shifts,27,600 sec. Avail.,1,x,daily,Sub-Assembly,1,Assembly,1,MRP,18,400,pcs/mo,-12,000 “L”,-6,400 “R”,Tray = 20 pcs,2 Shifts,Highland Manufacturing,Sheet Metal Housings,Current State,(Date),Daily ShipSchedule,Weekly Schedule,TT = 60 sec.,ManchesterAvenue,6-,weekForecast,Weeklyfax,ProductionControl,MRP,90/60/30,dayForecasts,DailyOrder,5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days,1 sec. 39 sec. 46 sec. 62 sec. 40 sec.,Lead Time=,23.6 days,Process Time= 188 sec,5.,What pull systems will be usedbetween disconnected processes?,不连贯,制程可以使用,何種,拉引系统？,What will this supermarket eliminate?,这个超市可以消除什么？,0,s,39,s,46,s,62,s,40,s,Takt time,60 seconds,Stamp Machine Weld Sub-assy Assy,(auto-feed),Where else can one-piece flow be implemented? The machine and weld processes?,还有别的地方可执行一件,流,吗？是车削和焊接,制程,吗？,Yes!,就是这里,I,Coils,5 days,I,4600,L,2400 R,I,1100,L,600 R,OCT = 62 sec,D/R = 62 sec,C/O = 0,REJ = 6%,U/T =100%,2 Shifts,27, 600 sec. Avail.,OCT = 40 sec,D/R = 40 sec,C/O = 0,REJ = 7%,U/T = 100%,2 Shifts,27,600 sec. Avail.,Shipping,Staging,I,I,I,1600,L,850 R,1200,L,640 R,2700,L,1440 R,FerrousMetals Co.,500,ft coils,Tues &,Thurs,Machine,1,OCT= 39 sec,D/R = 39 sec,C/O = 10 min,REJ = 4%,U/T= 100%,2 Shifts,27, 600 sec Avail.,MCT = 1 second,C/O = 1 hour,REJ = 3%,U/T = 85%,27,600 sec. avail.,EPE = 2 weeks,Stamp,200,t,Weld,1,OCT = 46 sec,D/R = 46 sec,C/O = 10 min,REJ = 5%,U/T = 80%,2 Shifts,27,600 sec. Avail.,1,x,daily,Sub-Assembly,1,Assembly,1,MRP,18,400,pcs/mo,-12,000 “L”,-6,400 “R”,Tray = 20 pcs,2 Shifts,Highland Manufacturing,Sheet Metal Housings,Current State,(Date),Daily ShipSchedule,Weekly Schedule,TT = 60 sec.,ManchesterAvenue,6-,weekForecast,Weeklyfax,ProductionControl,MRP,90/60/30,dayForecasts,DailyOrder,5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days,1 sec. 39 sec. 46 sec. 62 sec. 40 sec.,Lead Time=,23.6 days,Process Time= 188 sec,Where else can one-piece flow be implemented?,还有别的地方可执行一件吗？,By establishingone-piece flowhere, what goes away?,这里用一件流，什么会消失？,VRK,0,s,39,s,46,s,62,s,40,s,Takt time,60 seconds,Stamp Machine Weld Sub-assy Assy,(auto-feed),Where else can one-piece flow be implemented? The assembly processes?,还有别的地方可执行一件,流,吗？是组,裝制程,吗？,Yes!,正是,I,Coils,5 days,I,4600,L,2400 R,I,1100,L,600 R,OCT = 62 sec,D/R = 62 sec,C/O = 0,REJ = 6%,U/T =100%,2 Shifts,27, 600 sec. Avail.,OCT = 40 sec,D/R = 40 sec,C/O = 0,REJ = 7%,U/T = 100%,2 Shifts,27,600 sec. Avail.,Shipping,Staging,I,I,I,1600,L,850 R,1200,L,640 R,2700,L,1440 R,FerrousMetals Co.,500,ft coils,Tues &,Thurs,Machine,1,OCT= 39 sec,D/R = 39 sec,C/O = 10 min,REJ = 4%,U/T= 100%,2 Shifts,27, 600 sec Avail.,MCT = 1 second,C/O = 1 hour,REJ = 3%,U/T = 85%,27,600 sec. avail.,EPE = 2 weeks,Stamp,200,t,Weld,1,OCT = 46 sec,D/R = 46 sec,C/O = 10 min,REJ = 5%,U/T = 80%,2 Shifts,27,600 sec. Avail.,1,x,daily,Sub-Assembly,1,Assembly,1,MRP,18,400,pcs/mo,-12,000 “L”,-6,400 “R”,Tray = 20 pcs,2 Shifts,Highland Manufacturing,Sheet Metal Housings,Current State,(Date),Daily ShipSchedule,Weekly Schedule,TT = 60 sec.,ManchesterAvenue,6-,weekForecast,Weeklyfax,ProductionControl,MRP,90/60/30,dayForecasts,DailyOrder,5,days 7.6 days 1.8 days 2.7 days 2 days 4.5 days,1,sec. 39 sec. 46 sec. 62 sec. 40 sec.,Lead Time=,23.6 days,Process Time= 188 sec,Where else can one-piece flow be implemented? The assembly processes?,还有别的地方可执行一件,流,吗？是组,裝制程,吗？,By establishingone-piece flowhere, what goes away?,这里用一件流，什么会消失？,VRK,187,seconds work = 3.1 operators,60 seconds TAKT,= 4 operators,= 3 operators,(target),Where else can one-piece flow be implemented? Lets look at OCT to evaluate:,还有别的地方可执行一件流吗？看看操作员周期时间？,5,days 7.6 days 1.8 days 2.7 days 2 days 4.5 days,1,sec. 39 sec. 46 sec. 62 sec. 40 sec.,MCT,OCT,OCT,OCT,OCT,What is the total humanwork content to machine, weldand assemble one housing?,完成一件的总人工时间是多久？,39 + 46 + 62 + 40 = 187,seconds,But customer needs a housingevery 60 seconds,但是顾客每,60,秒需要一件,More important to assign 4,th,operator to other meaningful work,第四位操作员做其它有意义的工作比较重要,Takt time,60 seconds,Machine Weld,Weld,Sub-Assembly,Assembly,60,secs. 60 secs. 54 secs.,58,x 3 = 174 seconds,Highland Operator Loading Chart Future-State,未来状态的操作员负荷表,I,Coils,5 days,I,4600,L,2400 R,I,1100,L,600 R,OCT = 62 sec,D/R = 62 sec,C/O = 0,REJ = 6%,U/T =100%,2 Shifts,27, 600 sec. Avail.,OCT = 40 sec,D/R = 40 sec,C/O = 0,REJ = 7%,U/T = 100%,2 Shifts,27,600 sec. Avail.,Shipping,Staging,I,I,I,1600,L,850 R,1200,L,640 R,2700,L,1440 R,FerrousMetals Co.,500,ft coils,Tues &,Thurs,Machine,1,OCT= 39 sec,D/R = 39 sec,C/O = 10 min,REJ = 4%,U/T= 100%,2 Shifts,27, 600 sec Avail.,MCT = 1 second,C/O = 1 hour,REJ = 3%,U/T = 85%,27,600 sec. avail.,EPE = 2 weeks,Stamp,200,t,Weld,1,OCT = 46 sec,D/R = 46 sec,C/O = 10 min,REJ = 5%,U/T = 80%,2 Shifts,27,600 sec. Avail.,1,x,daily,Sub-Assembly,1,Assembly,1,MRP,18,400,pcs/mo,-12,000 “L”,-6,400 “R”,Tray = 20 pcs,2 Shifts,Highland Manufacturing,Sheet Metal Housings,Current State,(Date),Daily ShipSchedule,Weekly Schedule,TT = 60 sec.,ManchesterAvenue,6-,weekForecast,Weeklyfax,ProductionControl,MRP,90/60/30,dayForecasts,DailyOrder,5,days 7.6 days 1.8 days 2.7 days 2 days 4.5 days,1,sec. 39 sec. 46 sec. 62 sec. 40 sec.,Lead Time=,23.6 days,Process Time= 188 sec,Where else can one-piece flow be implemented now that we have looked at OCT?,看过操作员周期时间后，还有别的地方可执行一件流吗？,By establishingone-piece flowhere, what goes away?,这里用一件流，什么会消失？,VRK,STD WK,38% Prod. Imp,SMED,95%,STD WK,38% Prod. Imp,SMED,95%,STD WK,38% Prod. Imp,SMED,95%,STD WK,38% Prod. Imp,SMED,95%,STD WK,38% Prod. Imp,SMED,95%,STD WK,38% Prod. Imp,SMED,10 min,6-,weekForecast,Weeklyfax,ProductionControl,MRP,90/60/30,dayForecasts,DailyOrder,60,We will need to use a signal kanban for batch processes that have changeover times,对于换模时间较长的批量制程，必须使用讯号看板,batch,Stamp,Shipping,Housing Cell,1x,daily,Ferrous,Metals Co.,Tues &,Thurs,18,400 pcs/mo,-12,000 “L”,- 6,400 “R”.,Tray = 20 pcs,2 shifts,OCT =