VSM价值流培训教材

Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,VSM-,价值流,-,最好的价,值,值流教程,2010,年,12,月,6,日,何为,VSM,？,VSM,（,Value StreamMapping,）价值流,程,程图是丰,田,田精实制,造,造（,Learn Manufacturing,）生产系,统,统框架下,的,的一种用,来,来描述物,流,流和信息,流,流的形象,化,化工具,价值的定,义,义,只有顾客,才,才能定义,价,价值,对整个产,品,品定义价,值,值,再次挑战,和,和重新思,考,考价值,确定目标,成,成本（去,除,除目前所,有,有的浪费,）,）,价值吸引,更,更多的顾,客,客,利润,成本,价格,价格,价格,价格,利润,成本,传统思想,成本,+,利润 =价格,精益思想,价格 成本 =利润,典型的公,司,司,真相,从顾客的,观,观点看，,大,大部分公,司,司非增值,活,活动的总,量,量大约为,95%,Mine,矿山,开采,熔炼,热轧,冷轧,制罐,储存,罐装,储存,Tesco,超市库存,Tesco,超市,消费者,再熔炼,回收,可乐罐的,价,价值流,加工时间3,hours,储存和运,输,输时间11,months,累计报废24%,这是发达,公,公司运营,的,的很现代,的,的价值流,可乐罐的,价,价值流,产业,玻璃制品,食品,纺织,金属,电子,消费产品,生产支持,步骤,72,37,105,187,239,105,98,增值,6,4,11,13,19,10,15,%,8,11,10,7,8,10,15,价值分析,案,案例,精益技术,价值流图,提供容易,理,理解的可,视,视的图，,表,表达什么,是,是顾客的,价,价值，及,提,提供价值,的,的过程的,流,流动细节,目前状态,将来状态,为什么画,图,图？,单个的价,值,值流可视,化,化,应用一组,工,工具来评,审,审价值流,跨职能的,参,参与和决,策,策,理解存在,什,什么浪费,和,和在哪里,可以开发,改,改进的计,划,划,价值流图,一个特定,的,的产品，,工,工作单元,或,或产品族,/,工作单元,族,族，使用,符,符号或图,表,表用视觉,表,表示其材,料,料和信息,的,的流动,过程,1,过,程,程,2,过,程,程,3,供,方,方,顾,客,客,上,游,游,下,游,游,价,值,值,流,流,图,图,要,要,点,点,通,常,常,在,在,巡,巡,视,视,时,时,收,收,集,集,信,信,息,息,先,快,快,速,速,浏,浏,览,览,门,门,对,对,门,门,情,情,况,况,从,发,发,货,货,点,点,和,和,工,工,作,作,上,上,游,游,开,开,始,始,自,己,己,计,计,算,算,（,（,回,回,避,避,系,系,统,统,里,里,的,的,数,数,字,字,）,）,自,己,己,做,做,整,整,个,个,流,流,程,程,用,笔,笔,纸,纸,-,整,个,个,路,路,线,线,拒,绝,绝,电,电,脑,脑,为,什,什,么,么,自,自,己,己,动,动,手,手,?,没,有,有,延,延,迟,迟,你,作,作,，,，,你,你,理,理,解,解,重,点,点,是,是,流,流,动,动,，,，,而,而,不,不,是,是,电,电,脑,脑,修,正,正,自,自,己,己,的,的,错,错,误,误,微,微,调,调,的,的,技,技,能,能,目,前,前,价,价,值,值,流,流,图,图,将,来,来,价,价,值,值,流,流,图,图,产,品,品,族,族,目,前,前,状,状,态,态,图,图,将,来,来,状,状,态,态,图,图,工,作,作,计,计,划,划,价,值,值,流,流,图,图,步,步,骤,骤,产,品,品,族,族,在,下,下,游,游,过,过,程,程,中,中,通,通,过,过,共,共,同,同,加,加,工,工,步,步,骤,骤,及,及,应,应,用,用,共,共,同,同,设,设,备,备,的,的,一,一,组,组,产,产,品,品,产,品,品/,过,过,程,程,矩,矩,阵,阵,产,品,品,过,过,程,程,矩,矩,阵,阵,创,立,立,产,产,品,品,通,通,过,过,的,的,产,产,品,品,和,和,过,过,程,程,（,（,设,设,备,备,）,）,的,的,矩,矩,阵,阵.,包括要求和,成,成本/价格,数,数据，根据,实际的,顾客要求,相关的路径,，,，确保验证,，,，不要推测.,将相似的产,品,品合成组，,根,根据扩大成,本,本,80/20,法则选择产品族,作,作价值流图,“对受益,最,最大的影响,”,”,Extended Cost,$40k,$50k,$30k,$10k,$10k,$5k,$15k,绘制步骤,1.,绘制客户、,供,供应商和生,产,产控制部门,首先将客户,的,的图标画在,价,价值流图的,右,右上角，以,同,同样的图标,表,表示供应商,画,画在价值流,图,图的左上角,，,，在客户和,供,供应商之间,画,画上生产控,制,制部门,第一步,2.,绘制客户需,求,求信息,在客户图标,下,下画一个数,据,据库，将客,户,户的需求填,入,入其中，包,括,括每种产品,的,的月需求和,日,日需求，以,及,及每天多少,箱,箱产品。,第二步,3.绘制发,货,货与收货信,息,息,首先在客户,下,下方画出卡,车,车图标，并,在,在卡车图标,内,内填上发货,的,的频率，然,在,在客户卡车,图,图标的下方,画,画上发货图,标,标，并画出,一,一条箭线从,发,发货图标其,过,过客户卡车,图,图标指向客,户,户图标。,供应商等样,于,于客户,第三步,4.绘制各,工,工序信息,1)图形的,底,底部用矩形,图,图标表示出,各,各道工序，,将,将最上游的,工,工序画在最,左,左边，最下,游,游的画在最,右,右边。每个,工,工序图标内,可,可标注工序,的,的相关信息,，,，如操作人,数,数、机器数,。,。,2)在每个,工,工序图标的,下,下面画上数,据,据框，并填,入,入相关信息,。,。通常包括,该,该工序的加,工,工周期，换,模,模时间、有,效,效作业时间,、,、使用率。,3）在各工,序,序的数据框,下,下方画一条,有,有凹凸的折,线,线，并把每,道,道工序的增,值,值时间，填,写,写在每个数,据,据框下方的,时,时间线上。,第四步,5、绘制信,息,息流,1）画出客,户,户图标到生,产,产控制部门,之,之间的信息,沟,沟通箭线。,一,一般信息的,流,流动有电子,和,和自手工方,式,式两种，在,价,价值流上分,别,别以带折线,的,的箭头和直,线,线箭头表示,。,。在大多数,情,情况下，信,息,息在客户和,供,供应商之间,以,以电子化的,形,形式流动。,2）同时，,画,画出生产控,制,制部门图标,到,到供应商之,间,间的箭线，,用,用来代表生,产,产控制部门,发,发布的预测,和,和订单信息,，,，并把信息,发,发布的频率,标,标注在箭线,上,上。,第五步,2）在生产,控,控制部门图,标,标和代表生,产,产主管的方,框,框之间画一,条,条信息沟通,的,的箭线，并,把,把主管发布,计,计划的频率,标,标注在箭头,上,上。,3）在代表,生,生产主管的,方,方框和相关,的,的工序方框,之,之间若干信,息,息沟通的箭,线,线，并把相,关,关工序的发,布,布信息的频,率,率组在每条,箭,箭线上。,6.绘制在,制,制品库存和,物,物料流动,1)在工序,之,之间在制品,或,或成品的位,置,置上画上库,存,存图标，并,在,在库存图标,的,的下方标注,库,库存的数量,。,。,2）计算各,工,工序间库存,存,存储的天数,，,，并将计算,结,结果填写在,该,该工序方框,下,下方的时间,上,上。,公式为,库存储备天,数,数=两个工,序,序间的库存,总,总数/每天,发,发运的产品,数,数量,3）在价值,流,流图上画出,有,有推动、拉,动,动和先进先,出,出通道的地,方,方。,第六步,产品族,目前状态图,将来状态图,工作计划,价值流图步,骤,骤,200,吨压轧机,焊接,II,焊接,I,压轧部门,组装部门,.,钢卷库,=,篮子里的半,成,成品,=,盘子里的产,成,成品,焊接零件库,终检,ACME,冲压厂布局,组装,II,组装,I,焊接部门,.,冲压件,产成品库,发货,焊接检测区,域,域,从哪里开始,？,？,ACME,冲压材料流,程,程,冲压,#1,点焊工作站,#2,点焊工作站,#1,组装工作站,#2,组装工作站,发货,顾客信息,加工流信息,供方信息,产品控制信息,时间线,地理布局图,顾客要求,State Street,AssemblySS,图表,18,400 pcs/mo,- 12,000 LH,- 6,400 RH,Tray = 20 pcs,2 shifts,920 pcs/day,从顾客开始,组装公司,每月,18,400,件,- 12,000 Type LH,- 6,400TypeRH,每月,20,天,每盘,20,件,两班工作制,一天,1,卡车,18,400 / 20 = 920/,天,State Street,Assembly,18,400 pcs/mo,- 12,000 LH,- 6,400 RH,Tray = 20 pcs,2 shifts,920 pcs/day,目前状态图,1x,Daily,1x,Daily,SHIPPING,Staging,I,2700 L,1440 R,I,发货,ACME,冲压加工,每天,1,卡车,20,件,/,盘,10,盘,/,托架,30 “L,”,”,盘,/,天,16 “R,”,”,盘,/,天,存货,- 2700 L,- 1440 R,SHIPPING,I,2700L,1440R,Staging,1x,Daily,目前状态图,State Street,Assembly,18,400 pcs/mo,- 12,000 LH,- 6,400 RH,Tray = 20 pcs,2 shifts,920 pcs/day,收集加工数,据,据,各类产品的,数,数量,使用的机器,操作时间,换产周期,正常运行时,间,间（所要求,的,的机器时间,）,）,操作者数量,（,（敬业的）,包装尺寸,工作时间（,减,减去休息时,间,间）,报废率,#2,组装,图表,ASSEMBLY #2,1,C/T = 40,seconds,C/O = 0,Uptime = 100%,2 Shifts,27,600 sec/shift,1200 L,640 R,I,ACME,冲压加工,2,个部件号,1,个操作者,2,班制,没有设置,40,秒操作时间,100%,正常运行使,用,用,2,次休息,每次,10,分钟,库存,:,-1200LH,-640RH,ASSEMBLY#2,1,C/T = 40 seconds,C/O = 0,Uptime = 100%,2 Shifts,27,600 sec/shift,I,1200L,640R,目前,状,状态,图,图,State Street,Assembly,18,400 pcs/mo,- 12,000 LH,- 6,400 RH,Tray = 20 pcs,2 shifts,920 pcs/day,1x,Daily,Staging,SHIPPING,I,2700L,1440R,#1,组装,图表,:,ASSEMBLY#1,1,C/T = 62 seconds,C/O = 0,Uptime = 100%,2 Shifts,27,600 sec/shift,I,1600 L,850 R,ACME,冲压,加,加工,2,个部,件,件号,1,个操,作,作者,2,班制,没有,设,设置,62,秒操,作,作时,间,间,100%,正常,运,运行,使,使用,2,次休,息,息,每次,10,分钟,库存,:,-1600LH,-850RH,ASSEMBLY#1,1,C/T=62seconds,C/O=0,Uptime=100%,2Shifts,27,600sec/shift,I,1600L,850R,目前,状,状态,图,图,State Street,Assembly,18,400 pcs/mo,- 12,000 LH,- 6,400 RH,Tray = 20 pcs,2 shifts,920 pcs/day,1x,Daily,SHIPPING,Staging,I,2700L,1440R,ASSEMBLY#2,1,C/T = 40 seconds,C/O = 0,Uptime = 100%,2 Shifts,27,600 sec/shift,I,1200L,640R,#2,点焊,:,图表,:,S.WELD#2,1,C/T = 46 seconds,C/O = 10 min.,Uptime = 80%,2 Shifts,27,600 sec/shift,I,1100 L,600 R,ACME,冲压,加,加工,2,个部,件,件号,1,操作,者,者,2,班制,10,分钟设置,46,秒操作时,间,间,80%,正常运行,使,使用时间,2,次休息,每次,10,分钟,库存,:,- 1100 LH,-600RH,目前状态,图,图,C/T = 62 seconds,C/O = 0,Uptime = 100%,2 Shifts,27,600 sec/shift,S. WELD #2,1,C/T = 46 seconds,C/O = 10 minutes,Uptime = 80%,2 Shifts,27,600 sec/shift,1100 L,600 R,State Street,Assembly,18,400 pcs/mo,- 12,000 LH,- 6,400 RH,Tray = 20 pcs,2 shifts,920 pcs/day,1x,Daily,SHIPPING,Staging,I,2700 L,1440 R,ASSEMBLY #2,1,C/T = 40 seconds,C/O = 0,Uptime = 100%,2 Shifts,27,600 sec/shift,I,1200 L,640 R,ASSEMBLY #1,1,1600 L,850 R,I,I,#1,点焊,:,图表,:,S.WELD #1,1,C/T = 39 seconds,C/O = 10 min.,Uptime = 100%,2 Shifts,27,600 sec/shift,I,4600 L,2400 R,ACME,冲压加工,2,个部件号,1,个操作者,2,班制,10,分钟设置,39,秒操作时,间,间,100%,正常运行,使,使用时间,2,次休息,每次,10,分钟,库存,:,- 4600 LH,- 2400 RH,目前状态,图,图,SHIPPING,ASSEMBLY #1,1,C/T = 62 seconds,C/O = 0,Uptime = 100%,2 Shifts,27,600 sec/shift,S. WELD #1,4600 L,2400 R,1,C/T = 39 seconds,C/O = 10 minutes,Uptime = 100%,2 Shifts,27,600 sec/shift,I,Staging,State Street,Assembly,18,400 pcs/mo,- 12,000 LH,- 6,400 RH,Tray = 20 pcs,2 shifts,920 pcs/day,1x,Daily,I,ASSEMBLY #2,1,C/T = 40 seconds,C/O = 0,Uptime = 100%,2 Shifts,27,600 sec/shift,I,1200 L,640 R,I,1600 L,850 R,I,S. WELD #2,1,C/T = 46 seconds,C/O = 10 minutes,Uptime = 80%,2 Shifts,27,600 sec/shift,1100 L,600 R,冲压,:,图表,:,STAMPING,C/T = 1 second,C/O = 1 hour,Uptime = 85%,EPE = 2 weeks,27,600 sec/shift,I,Coils,5 days,200T,ACME,冲压加工,200Ton,冲压机,自动上卷,每两个星,期,期运行一,次,次,1,个小时设,置,置,1,秒操作时,间,间,85%,正常运行,时,时间,2,次休息,每次,10,分钟,库存,:,- 5,天的钢卷,目前状态,图,图,SHIPPING,Staging,STAMPING,I,Coils,5 days,C/T = 1 seconds,C/O = 1 hour,Uptime = 85%,27,600 sec./shift,EPE = 2 weeks,200 T,STAMPING,State Street,Assembly,18,400 pcs/mo,- 12,000 LH,- 6,400 RH,Tray = 20 pcs,2 shifts,920 pcs/day,1x,Daily,I,ASSEMBLY #2,1,C/T = 40 seconds,C/O = 0,Uptime = 100%,2 Shifts,27,600 sec/shift,I,1200 L,640 R,ASSEMBLY #1,1,C/T = 62 seconds,C/O = 0,Uptime = 100%,2 Shifts,27,600 sec/shift,S. WELD #2,1,C/T = 46 seconds,C/O = 10 minutes,Uptime = 80%,2 Shifts,27,600 sec/shift,1100 L,600 R,I,1600 L,850 R,I,S. WELD #1,4600 L,2400 R,1,C/T = 39 seconds,C/O = 10 minutes,Uptime = 100%,2 Shifts,27,600 sec/shift,I,Tues. +,Thurs,Michigan,Steel Co.,500 ft. coils,加入供方,MichiganSteel Co,:,星期二一,卡,卡车,星期四一,卡,卡车,500,英尺钢卷,目前状态,图,图,SHIPPING,C/T = 62 seconds,C/O = 0,Uptime = 100%,2 Shifts,27,600 sec/shift,Staging,Michigan,Steel Co.,500 ft. coils,Tues. +,Thurs.,这是材料流,进门,门对门价值流,出门,State Street,Assembly,18,400 pcs/mo,- 12,000 LH,- 6,400 RH,Tray = 20 pcs,2 shifts,920 pcs/day,1x,Daily,I,ASSEMBLY #2,1,C/T = 40 seconds,C/O = 0,Uptime = 100%,2 Shifts,27,600 sec/shift,I,1200 L,640 R,ASSEMBLY #1,1,S. WELD #2,1,C/T = 46 seconds,C/O = 10 minutes,Uptime = 80%,2 Shifts,27,600 sec/shift,1100 L,600 R,1600 L,850 R,I,S. WELD #1,4600 L,2400 R,1,C/T = 39 seconds,C/O = 10 minutes,Uptime = 100%,2 Shifts,27,600 sec/shift,I,STAMPING,I,Coils,5 days,C/T = 1 seconds,C/O = 1 hour,Uptime = 85%,27,600 sec./shift,EPE = 2 weeks,200 T,STAMPING,I,Acme,生产控制,:,图表,:,PRODUCTION,CONTROL,MRP,Daily,Order,Weekly,Schedule,加入信息,流,流,来自顾客,的,的预测,/30/60/90,天,每日确认,订,订货,每周产生,MRP,6,周的预测,给,给供方,每周向供,方,方 确认,放,放行,每周计划,每日发货,计,计划,目前状态,图,图,SHIPPING,C/T = 62 seconds,C/O = 0,Uptime = 100%,2 Shifts,27,600 sec/shift,C/T = 39 seconds,C/O = 10 minutes,Uptime = 100%,2 Shifts,27,600 sec/shift,Staging,PRODUCTION,CONTROL,MRP,Daily,Order,30/60/90 day,Forecasts,Weekly,Release,6-week,Forecasts,Daily Ship,Schedule,Weekly Schedule,State Street,Assembly,18,400 pcs/mo,- 12,000 LH,- 6,400 RH,Tray = 20 pcs,2 shifts,920 pcs/day,1x,Daily,I,ASSEMBLY #2,1,C/T = 40 seconds,C/O = 0,Uptime = 100%,2 Shifts,27,600 sec/shift,I,1200 L,640 R,ASSEMBLY #1,1,S. WELD #2,1,C/T = 46 seconds,C/O = 10 minutes,Uptime = 80%,2 Shifts,27,600 sec/shift,1100 L,600 R,I,1600 L,850 R,I,S. WELD #1,4600 L,2400 R,1,C/T = 39 seconds,C/O = 10 minutes,Uptime = 100%,2 Shifts,27,600 sec/shift,I,STAMPING,I,Coils,5 days,C/T = 1 seconds,C/O = 1 hour,Uptime = 85%,27,600 sec./shift,EPE = 2 weeks,200 T,STAMPING,Michigan,Steel Co.,500 ft. coils,Tues. +,Thurs.,库存天数,=,现有量,日顾客需求,加入时间,线,线,生产周期,是,是所有在,各,各过程中,操,操作的时,间,间（增值,时,时间）,库存时间,是,是库存通,过,过价值流,排,排队的时,间,间,.,目前状态,图,图,C/T= 62seconds,C/O= 0,Uptime =100%,2 Shifts,27,600 sec/shift,1 second,39 sec.,62 sec.,40 sec.,Value,Added,Time,= 188 sec.,46 sec.,5 days,7.6days,1.8days,2.7days,2 days,4.5days,Production,Leadtime,23.6,days,=,State Street,Assembly,18,400 pcs/mo,- 12,000 LH,- 6,400 RH,Tray = 20 pcs,2 shifts,920 pcs/day,1x,Daily,SHIPPING,Staging,I,ASSEMBLY#2,1,C/T = 40 seconds,C/O = 0,Uptime = 100%,2 Shifts,27,600 sec/shift,I,1200L,640R,ASSEMBLY#1,1,I,1600L,850R,S. WELD#2,1,C/T= 46seconds,C/O= 10minutes,Uptime =80%,2 Shifts,27,600 sec/shift,1100L,600R,I,S. WELD#1,4600L,2400R,1,C/T= 39seconds,C/O= 10minutes,Uptime =100%,2 Shifts,27,600 sec/shift,I,STAMPING,I,Coils,5 days,C/T = 1 seconds,C/O = 1 hour,Uptime = 85%,27,600 sec./shift,EPE = 2 weeks,200 T,STAMPING,Michigan,Steel Co.,500 ft. coils,Tues. +,Thurs.,PRODUCTION,CONTROL,MRP,Weekly Schedule,Daily Ship,Schedule,4600L,2400R,7000,920=,7.6days,Daily,Order,30/60/90 day,Forecasts,Weekly,Release,6-week,Forecasts,识别机会,目前的状,态,态图表明,“,“正在”,所,所发生的,它展示了,浪,浪费的步,骤,骤和瓶颈,它帮助目,视,视操作者,如,如何能够,合,合并“流,动,动”,它帮助,你,你看到,哪,哪里需,要,要“拉,动,动”体,系,系,它帮助,如,如何改,进,进影响,价值流,价值流,图,图,“,将来的,状,状态,”,产品族,目前状,态,态图,将来状,态,态图,工作计,划,划,价值流,图,图步骤,将来状,态,态的问,题,题,要,求,1.,理想的操作时间,(,节拍时间,)?,2.,建立成品超市或直接发货,?,材料流,3.,哪里能够使用持续的流动,?,4.,哪里需要超市拉动系统,?,信息流,5.,哪个是“触发器”的过程,?,6.,如何均衡混合生产,?,7.,释放什么工作批量,?,改进,8.,哪里需改进来实现？,将来状,态,态的问,题,题,#1,什么是,节,节拍（,理,理想的,操,操作时,间,间 ）,?,节拍是,通,通过计,算,算生产,及,及最终,销,销售的,步,步伐把,顾,顾客与,生,生产相,连,连的工,具,具,精益生,产,产的目,的,的是按,顾,顾客的,频,频率生,产,产,，,不快也,不,不慢,无论或,快,快或慢,的,的生产,都,都会产,生,生浪费,与,与非增,值,值活动,节拍 =,可用时间,(,小时,/,秒,),顾客要求,(,单元),可用时,间,间,=,付费时,间,间,休息时,间,间,=8,小时,- 20,分钟,= 28,800- 1200,秒,= 27,600,秒,/,班,可用时,间,间,顾客要,求,求,=,27,600,秒,460,件每班,理想的,操,操作时,间,间（或,节,节拍）,= 60,秒,ACME,冲压节,拍,拍,将来状,态,态图问,题,题,#2,是否建,立,立成品,超,超市，,顾,顾客从,这,这里拉,动,动，或,直,直接发,货,货,?,顾客时,间,间表装,配,配,发货,顾客要,求,求,订单,组装,2.,直接发,货,货或超,市,市,?,当持续,流,流动使,用,用直接,发,发货，,可,可以混,合,合模式,生,生产,.,2.,直接发货或,超,超市,?,使用成品超,市,市，需要考,虑,虑以下因素,：,：,设置时间长,过程长或不,可,可靠,远距离外面,供,供货,发货,顾客要求,订单,拉动,超市,生产卡,组装,超市时间表,组,组装,2.,直接发货或,超,超市,?,将来状态图,#3,哪里能使用,持,持续流动过,程,程,?,3.,持续流动在,哪,哪里适用,?,找出可以合,并,并的增值的,操,操作,根据操作时,间,间和节拍判,断,断设备,平衡和改进,流,流动,10,20,30,40,50,OPERATIONS TIME IN SECONDS,PROCESS SEQUENCE,TIME,STEP,OPERATION DESCRIPTION,MAN MACH WALK,PRODUCT/ PART,OUTPUT RATE,MANUAL,OPERATION,MACHINE,PROCESS,WALKING,TIME,60,Stamping,1st Weld,2nd Weld,1st Assembly,2nd Assembly,1,2,3,4,5,Steering Bracket,60 s.,1,39,45,62,40,187 / 60 = 3.12 operators,运行分析表,TaktTime,改进后,:,目前的操作,时,时间,:,1,1,1,1,1,39s.,45s.,62s.,1s.,40s.,60,40,20,0,WELD1,WELD2,ASSEMBLE 1,ASSEMB. 2,60,= 1 +39+ 45+ 62+ 40,= 187/ 60= 3.12 Ops,= 186, improvement,= 168/ 60= 2.8 Ops,1,1,1,56s.,56s.,56s.,WELD,WELD,ASSEMBLE,ASSEMBLE,3. ACME,持续流动,将来状态问,题,题,#4,什么地方使,用,用超市拉动,系,系统来控制,上,上游过程的,生,生产,?,4.,超市放在哪,里,里,?,当需要时使,用,用生产超市,:,短的操作时,间,间,多样顾客,长时间设置,长或非可靠,的,的过程,远距离外面,供,供货,4. ACME,超市,冲压后,:,操作结速很,快,快，设置时,间,间很长,使用批次信,号,号看板（三,角,角式）来安,排,排超市并杜,绝,绝周计划,冲压前,:,供方尽量不,改,改变批次尺,寸,寸或一次运,货,货量,每次钢卷使,用,用完，发看,板,板给生产控,制,制,拉动原则的,超,超市系统,Supplier,Customer,Supermarket,Final assembly,Supermarket,Mechanicalproduction,Supermarket,物流,信息流,Pre assembly,Supermarket,将来状态图,问,问题,#5,生产链中在,什,什么点（“,触,触发器过程,”,”）开始计,划,划生产,?,5.,触发器放在,哪,哪里,?,触发器的过,程,程是在价值,流,流中你唯一,安,安排计划的,过,过程,它规定了步,调,调并从上游,过,过程开始拉,动,动,它的输出流,过,过下游的其,他,他过程,过程,1,过程,2,过程,3,过程,4,过程,1,过程,2,过程,3,过程,4,拉动,拉动,拉动,Pull,拉动,超市,超市,触发器,流动,流动,FIFO,触发器,FIFO,5.,选择触发器,将来状态问,题,题,#6,如何在触发,器,器过程平衡,混,混合生产,?,6.,如何平衡混,合,合产品,?,平衡混合产,品,品是在触发,器,器分配所有,产,产品在短的,时,时间周期的,均,均衡生产，,将,将会,:,对顾客反应,更,更快,更短生产周,期,期,较少超市库,存,存,没有高、低,谷,谷,较少加速,较少拒收,6. ACME,混合生产,每日需要,30,盘左驱动件,，,，,16,盘右驱动支,架,架,通常的批次计划是,:,1st shift2nd Shift,LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLRRRRRRRRRRRRRRRR,均衡（统一）计划是,:,1st shift2nd Shift,RLLRLLRLLRLLRLLRLLRLLRLLRLLRLLRLLRLLRLLRLLRLLR,均衡图表是,:,OXOX,在触发器过,程,程，什么工,作,作量（鼓点,/,批量）你将,持,持续释放并,收,收回,?,将,来,来,状,状,态,态,问,问,题,题,#7,7.,什,么,么,是,是,批,批,量,量,?,从,触,触,发,发,器,器,可,可,以,以,释,释,放,放,和,和,收,收,回,回,工,工,作,作,时,时,间,间,最,最,小,小,的,的,批,批,次,次,（,（,批,批,量,量,）,）,，,，,建,建,立,立,一,一,个,个,持,持,续,续,的,的,，,，,均,均,衡,衡,生,生,产,产,流,流,动,动,，,，,需,需,要,要,考,考,虑,虑,:,节,拍,拍,（,（,要,要,求,求,的,的,生,生,产,产,周,周,期,期,）,）,驱,驱,动,动,器,器,用,来,来,拉,拉,动,动,系,系,统,统,生,产,产,的,的,高,高,峰,峰,与,与,低,低,谷,谷,可,视,视,的,的,进,进,展,展,有,效,效,处,处,理,理,优,优,先,先,权,权,及,及,较,较,少,少,加,加,速,速,快,的,的,顾,顾,客,客,反,反,应,应,1,周,1,日,1,班,1,小,时,时,1,批,量,量,量,越,越,小,小,=,反,馈,馈,快,快,管,理,理,时,时,间,间,的,的,框,框,架,架,将,释,释,放,放,什,什,么,么,工,工,作,作,量,量,?,你,如,如,何,何,知,知,道,道,其,其,表,表,现,现,满,满,足,足,顾,顾,客,客,要,要,求,求,?,批,量,量,（,（,Pitch,）,在,触,触,发,发,器,器,过,过,程,程,决,决,定,定,生,生,产,产,的,的,平,平,稳,稳,性,性,如,如,何,何,根,据,据,包,包,装,装,尺,尺,寸,寸,可,可,以,以,计,计,算,算,(,节,拍,拍,X,包,装,装,数,数,量,量,=,最,少,少,批,批,量,量,),For ACME: 60,秒,X 20,件,= 20,分钟,每,批,批,量,量,一,一,个,个,柱,柱,子,子,(,假,设,设,20,分,钟,钟,),A,B,C,A,A,B,B,C,type,type,type,A,B,C,每,行,行,一,一,类,类,产,产,品,品,7:007:207:408:008:208:409:009:20,A,负,荷,荷,均,均,衡,衡,箱,箱,收,回,回,步,步,调,调,的,的,例,例,子,子,A,B,C,A,A,B,B,C,type,type,type,A,B,C,7:00 7:20 7:40 8:00 8:20 8:40 9:00 9:20,触,发,发,器,器,过,过,程,程,发货,l,拉动,1,提取下一个看板,2,放下看板,3,提取一组数量的包装,4,移动成品至超市,将,来,来,状,状,态,态,问,问,题,题,#8,对,价,价,值,值,流,流,需,需,做,做,什,什,么,么,过,过,程,程,改,改,进,进,才,才,能,能,实,实,现,现,所,所,设,设,计,计,的,的,将,将,来,来,状,状,态,态,?,8.,什,么,么,必,必,须,须,改,改,进,进,?,识,别,别,所,所,有,有,必,必,须,须,完,完,成,成,的,的,，,，,使,使,将,将,来,来,状,状,态,态,图,图,为,为,现,现,实,实,的,的,措,措,施,施,项,项,目,目,每,个,个,项,项,目,目,展,展,示,示,在,在,图,图,上,上,用,用,图,图,表,表,显,显,示,示,:,焊,接,接,更,更,换,换,实,现,现,将,将,来,来,状,状,态,态,Kaizen,持,续,续,改,改,进,进,产,品,品,族,族,目,前,前,状,状,态,态,图,图,将,来,来,状,状,态,态,图,图,工,作,作,计,计,划,划,价,值,值,流,流,图,图,步,步,骤,骤,ACME,所,需,需,的,的,改,改,进,进,焊,接,接,/,组,装,装,区,区,减,少,少,工,工,作,作,内,内,容,容,至,至,168,秒,或,或,更,更,少,少,减,少,少,焊,焊,工,工,的,的,设,设,置,置,时,时,间,间,至,至,1,分,钟,钟,或,或,更,更,少,少,增,加,加,焊,焊,工,工,正,正,常,常,运,运,转,转,时,时,间,间至,100%,图,标,标,:,消,除,除,浪,浪,费,费,焊,工,工,的,的,更,更,换,换,焊,工,工,的,的,正,正,常,常,运,转,转,时,时,间,间,ACME,所,需,需,的,的,改,改,进,进,200T,冲,压,压,机,机,减,少,少,冲,冲,压,压,机,机,的,的,设,设,置,置,时,时,间,间,至,至,10,分,钟,钟,或,或,更,更,少,少,钢,材,材,供,供,方,方,改,为,为,每,每,日,日,供,供,货,货,图,标,标,:,200t,设,置,置,更,更,换,换,日,供,供,货,货,=4.5days,=169sec.,1x,Daily,SHIPPING,Staging,L,R,WELD+ASSY.,Takt=60sec.,C/O=0,Uptime=100%,2Shifts,Totalworkcontent168sec.,STAMPING,200T,coil,coil,tote,batch,Coils,Michigan,Steel Co.,500ft.coils,PRODUCTION,CONTROL,Daily,Order,6-week,Forecasts,coil,Daily,Milk Run,DailyOrder,20,20,20,OXOX,Daily,Order,30/60/90day,Forecasts,State Street,Assembly,18,400 pcs/mo,- 12,000 LH,- 6,400 RH,Tray = 20 pcs,2 shifts,(atthe,press),EPE=1shift,C/O=10min.,daily deliv.,-,1.5days,1sec,1day,168sec.,2days,Production,leadtime,Value,AddedTime,Pull,changeover,welder,uptime,welder,changeover,eliminate,waste,BP#1,Loop,BP#2,Loop,BP#3,Loop,将来,状,状态,图,图,ThankYou,演讲,完,完毕,，,，谢,谢,谢观,看,看！,