豐田培訓(xùn)系列教材—價(jià)值流VSM.

1、香港現(xiàn)代俊銘企管HK Modern JunMing Enterprise Management專業(yè) 用心 服務(wù)Professional Canniness Service1u何為VSM？uVSM （ Value Stream Mapping ）價(jià)值流程圖是豐田精實(shí)制造（Learn Manufacturing）生產(chǎn)系統(tǒng)框架下的一種用來(lái)描述物流和信息流的形象化工具 價(jià)值流香港現(xiàn)代俊銘企管HK Modern JunMing Enterprise Management專業(yè) 用心 服務(wù)Professional Canniness Service2 價(jià)值的定義u 只有顧客才能定義價(jià)值u 對(duì)整個(gè)產(chǎn)品定義價(jià)值

2、u 再次挑戰(zhàn)和重新思考價(jià)值u 確定目標(biāo)成本（去除目前所有的浪費(fèi)）u 價(jià)值吸引更多的顧客 利潤(rùn) 成本 價(jià)格 價(jià)格 價(jià)格 價(jià)格 利潤(rùn) 成本 傳統(tǒng)思想 成本 + 利潤(rùn) = 價(jià)格 精益思想 價(jià)格 成本 = 利潤(rùn) 香港現(xiàn)代俊銘企管HK Modern JunMing Enterprise Management專業(yè) 用心 服務(wù)Professional Canniness Service3價(jià)價(jià) 值值 流流過(guò)過(guò) 程程總裝單元總裝單元過(guò)過(guò) 程程 焊接焊接過(guò)過(guò) 程程 沖壓沖壓成成 品品原原 材材 料料傳統(tǒng)思維中，我們總是從工廠內(nèi)部來(lái)考慮，從原材料開(kāi)始一直追蹤到產(chǎn)品的完成來(lái)檢查價(jià)值流。 也可以用價(jià)值流的方法來(lái)繪制業(yè)務(wù)

3、過(guò)程。1價(jià)值流繪制的定義香港現(xiàn)代俊銘企管HK Modern JunMing Enterprise Management專業(yè) 用心 服務(wù)Professional Canniness Service4設(shè)計(jì)原材料總裝廠發(fā)貨客戶2零件生產(chǎn)價(jià)值流包含的是特定產(chǎn)品從進(jìn)公司到發(fā)貨至客戶的所有要素 (包括增值的和非增值的)。需求價(jià)值流繪制的定義香港現(xiàn)代俊銘企管HK Modern JunMing Enterprise Management專業(yè) 用心 服務(wù)Professional Canniness Service5價(jià)值流繪制 (VSM) 是一個(gè)手工方法通過(guò)用特定的圖標(biāo)繪畫(huà)來(lái)表現(xiàn)整個(gè)價(jià)值流的過(guò)程，包括物流，信息流

4、和過(guò)程流。價(jià)值流繪制的定義 Finished GoodsAssemblyLayoutWeldingRolling 6-wk ForecastWeekly Order6 x / DayPC & L6-wk forecastDailyLevel Box DA1 DA2 DA3C/O Time =CT =TAKT Time3 ShiftsDT =Scrap =Stamping0 Overtime2 ShiftsMax Size# Material HandlersC/O Time =CT =TAKT Time3 ShiftsDT =Scrap / Rework =C/O Time =CT =TAKT

5、 Time3 ShiftsDT =Scrap / Rework=Small Lot# OperatorsCustomerX pcs / monthStd Pack Qty# ShiftsWIP =WIP =WIP =Steel SupplierInv .TimeProc .TimeTPc /t = ? days? days? days? days? days? days? days用生產(chǎn)周期表現(xiàn)將來(lái)狀態(tài)的物流，信息流和過(guò)程流。用生產(chǎn)周期表現(xiàn)將來(lái)狀態(tài)的物流，信息流和過(guò)程流。香港現(xiàn)代俊銘企管HK Modern JunMing Enterprise Management專業(yè) 用心 服務(wù)Profess

6、ional Canniness Service6毫無(wú)計(jì)劃地實(shí)施將會(huì)給企業(yè)帶來(lái)災(zāi)難毫無(wú)計(jì)劃地實(shí)施將會(huì)給企業(yè)帶來(lái)災(zāi)難價(jià)值流的繪制是幫助你找到浪費(fèi)，價(jià)值流的繪制是幫助你找到浪費(fèi)，觀察到整個(gè)流程狀態(tài)的簡(jiǎn)單工具。觀察到整個(gè)流程狀態(tài)的簡(jiǎn)單工具。注意整個(gè)流程，目的在于消除浪費(fèi)注意整個(gè)流程，目的在于消除浪費(fèi)為什么要繪制價(jià)值流? Finished GoodsAssemblyLayoutWeldingRolling 6-wk ForecastWeekly Order6 x / DayPC & L6-wk forecastDailyLevel Box DA1 DA2 DA3C/O Time =CT =TAKT Ti

7、me3 ShiftsDT =Scrap =Stamping0 Overtime2 ShiftsMax Size# Material HandlersC/O Time =CT =TAKT Time3 ShiftsDT =Scrap / Rework =C/O Time =CT =TAKT Time3 ShiftsDT =Scrap / Rework=Small Lot# OperatorsCustomerX pcs / monthStd Pack Qty# ShiftsWIP =WIP =WIP =Steel SupplierInv .TimeProc .TimeTPc /t = ? days?

8、 days? days? days? days? days? days快來(lái)繪制流程快來(lái)繪制流程 !3關(guān)注浪費(fèi)關(guān)注浪費(fèi) . . . . . . 關(guān)注流程關(guān)注流程香港現(xiàn)代俊銘企管HK Modern JunMing Enterprise Management專業(yè) 用心 服務(wù)Professional Canniness Service7u為觀察到物流，信息流和過(guò)程流提供了方法。u支持價(jià)值流層面和工廠層面不斷改進(jìn)行動(dòng)的優(yōu)先次序化。u為布局規(guī)劃的發(fā)展提供基礎(chǔ)。價(jià)值流繪制的目標(biāo)消除浪費(fèi)消除浪費(fèi)81還有還有.香港現(xiàn)代俊銘企管HK Modern JunMing Enterprise Management專業(yè) 用

9、心 服務(wù)Professional Canniness Service8繪制現(xiàn)在狀態(tài)繪制現(xiàn)在狀態(tài)分析現(xiàn)在狀態(tài)分析現(xiàn)在狀態(tài)并并設(shè)計(jì)將來(lái)狀態(tài)設(shè)計(jì)將來(lái)狀態(tài)84Tues. & Fri.PC & LWeekly OrderMRPMSSWeekly Order# times/daySteelSupplierSteelPin# pcs# daysor shiftsIIIIStampingDowntimeChangeover Time=4 hr2 ShiftsTAKT = 2 Presses Cycle Time =ChangeOverWeldingLayoutScrap/ReworkDowntime = 20

10、%Uptime# OperatorsCycle Time =Weekly Build ScheduleDaily ShipSchedule6 Week Rolling Forecast6 Week Rolling ForecastFinished GoodsOvertime =# Shifts =AssemblyDT, ScrapReworkWIP = Cycle Time =TAKT = Changeover Time =Layout = 10% Scrap? days? days? days? days? days? days? daysInventory TimeProcessing T

11、imeTPc /t = ?TAKT = WIP = WIP = WIP =X pcs /monthStd. Pack Qty.# shiftsCustomer Finished GoodsAssemblyLayoutWeldingRolling 6-wk ForecastWeekly Order6 x / DayPC & L6-wk forecastDailyLevel Box DA1 DA2 DA3C/O Time =CT =TAKT Time3 ShiftsDT =Scrap =Stamping0 Overtime2 ShiftsMax Size# Material HandlersC/O

12、 Time =CT =TAKT Time3 ShiftsDT =Scrap / Rework =C/O Time =CT =TAKT Time3 ShiftsDT =Scrap / Rework=Small Lot# OperatorsCustomerX pcs / monthStd Pack Qty# ShiftsWIP =WIP =WIP =Steel SupplierInv.TimeProc.TimeTPc/t = ? days? days? days? days? days? days? days制作一個(gè)可實(shí)施的計(jì)劃并認(rèn)真地制作一個(gè)可實(shí)施的計(jì)劃并認(rèn)真地加以執(zhí)行！加以執(zhí)行！1ST 2ND

13、 3RD 4TH 1ST 2ND 3RD 4TH確定Tank Assy的節(jié)拍和流程 減少?zèng)_壓的設(shè)置時(shí)間減少?zèng)_壓的緩沖區(qū)將 Assy 移至工廠 10確定 Sender Assy的節(jié)拍和流程使 Sender Assy實(shí)行拉動(dòng)培訓(xùn)19992000行動(dòng)計(jì)劃行動(dòng)計(jì)劃價(jià)值流繪制的過(guò)程香港現(xiàn)代俊銘企管HK Modern JunMing Enterprise Management專業(yè) 用心 服務(wù)Professional Canniness Service9選擇一個(gè)價(jià)值流（產(chǎn)品族）組成一個(gè)小組理解客戶的需求繪制過(guò)程流繪制物料流繪制信息流計(jì)算產(chǎn)品總的生產(chǎn)周期TPCT具體的實(shí)施措施步驟 1:步驟 2:步驟 3:步驟

14、 4:步驟 5:步驟 6:步驟 7:步驟 8:現(xiàn)在狀態(tài)的繪制的步驟香港現(xiàn)代俊銘企管HK Modern JunMing Enterprise Management專業(yè) 用心 服務(wù)Professional Canniness Service10u定義價(jià)值流 (產(chǎn)品族)從客戶端開(kāi)始確定價(jià)值流產(chǎn)品必須經(jīng)過(guò)相似的工藝流程并且以相同的要求結(jié)束門(mén)到門(mén)的范圍（在廠內(nèi)的價(jià)值流）u列出零件數(shù)步驟1:選擇一個(gè)價(jià)值流（產(chǎn)品族）現(xiàn)在狀態(tài)的繪制的步驟香港現(xiàn)代俊銘企管HK Modern JunMing Enterprise Management專業(yè) 用心 服務(wù)Professional Canniness Service11

15、u選擇組織一個(gè)綜合職能的小組u選擇熟悉產(chǎn)品的小組成員u確保小組成員已接受過(guò)使 用價(jià)值流圖的培訓(xùn)u任命負(fù)責(zé)人(通常是業(yè)務(wù)線經(jīng)理)步驟 2: 組成一個(gè)小組 生產(chǎn)部綜合職能小組物料部維修維護(hù)領(lǐng)導(dǎo)支持產(chǎn)品工程工藝工程Sensei先生顧問(wèn)這是一個(gè)標(biāo)準(zhǔn)這是一個(gè)標(biāo)準(zhǔn)84現(xiàn)在狀態(tài)的繪制的步驟香港現(xiàn)代俊銘企管HK Modern JunMing Enterprise Management專業(yè) 用心 服務(wù)Professional Canniness Service12u每一個(gè)零件的計(jì)劃u工藝工程預(yù)算產(chǎn)能u生產(chǎn)的控制（每月/每周的預(yù)測(cè)）u生產(chǎn)的歷史（分析每天的差異，月度間的差異）u銷售（產(chǎn)品更改，新業(yè)務(wù)等） 步驟 3

16、: 理解客戶需求客戶名稱月度/年度需求:零件 A =零件 B =零件 C =# of 班次 =81現(xiàn)在狀態(tài)的繪制的步驟香港現(xiàn)代俊銘企管HK Modern JunMing Enterprise Management專業(yè) 用心 服務(wù)Professional Canniness Service13 客戶Demand/month:Part A =Part B =Part C =# of shifts =步驟 4: 繪制過(guò)程流InventoryPart A =Part B =Part C =# of shifts =發(fā)運(yùn)總裝焊接沖壓Takt =C.T. =D.T. =FTQ = 90%C/O Time

17、=Lot Size =# of ShiftsWIP =Takt =C.T. =D.T. = 20%FTQ =C/O Time =Lot Size =# of ShiftsWIP =Takt =C.T. =D.T. = FTQ =C/O Time = 4 hrs.Lot Size =# of ShiftsWIP =換型停機(jī)時(shí)間一次質(zhì)量現(xiàn)在狀態(tài)的繪制的步驟香港現(xiàn)代俊銘企管HK Modern JunMing Enterprise Management專業(yè) 用心 服務(wù)Professional Canniness Service14步驟 5: 繪制物料流客戶Demand/month:Part A = 7

18、05 pcs.Part B = 600 pcs.Part C = 1650 pcs.# of shifts =InventoryPart A = 750 pcsPart B = 600 pcsPart C = 1650 pcs# of shifts =發(fā)運(yùn)總裝焊接沖壓Takt =C.T. =D.T. =FTQ = 90%C/O Time =Lot Size =# of ShiftsWIP = 550 pcs.Takt =C.T. =D.T. = 20%FTQ =C/O Time =Lot Size =# of ShiftsWIP = 60 pcs.Takt =C.T. =D.T. = FTQ

19、=C/O Time = 4 hrs.Lot Size =# of ShiftsWIP = 25 pcs. 換型 停機(jī)時(shí)間一次質(zhì)量IIII2 x/day2 x/week供應(yīng)商1,200 pcs1,500 pcs800 pcs500 pcs現(xiàn)在狀態(tài)的繪制的步驟香港現(xiàn)代俊銘企管HK Modern JunMing Enterprise Management專業(yè) 用心 服務(wù)Professional Canniness Service15客戶Demand/month:Part A = 705 pcs.Part B = 600 pcs.Part C = 1650 pcs.# of shifts =Inven

20、toryPart A = 750 pcsPart B = 600 pcsPart C = 1650 pcs# of shifts =發(fā)運(yùn)總裝焊接沖壓Takt =C.T. =D.T. =FTQ = 90%C/O Time =Lot Size =# of ShiftsWIP = 550 pcs.Takt =C.T. =D.T. = 20%FTQ =C/O Time =Lot Size =# of ShiftsWIP = 60 pcs.Takt =C.T. =D.T. = FTQ =C/O Time = 4 hrs.Lot Size =# of ShiftsWIP = 25 pcs. 換型 停機(jī)時(shí)間

21、一次質(zhì)量IIII2 x/day2 x/week供應(yīng)商1,200 pcs1,500 pcs800 pcs500 pcsPC & LWeekly Build ScheduleDaily Ship Schedule6 week rolling forecast6 week rolling forecastWeekly OrderWeekly Order步驟 6: 繪制信息流現(xiàn)在狀態(tài)的繪制的步驟香港現(xiàn)代俊銘企管HK Modern JunMing Enterprise Management專業(yè) 用心 服務(wù)Professional Canniness Service16步驟 7: 計(jì)算總生產(chǎn)周期（TPCT

22、 客戶Demand/month:Part A = 705 pcs.Part B = 600 pcs.Part C = 1650 pcs.# of shifts =InventoryPart A = 750 pcsPart B = 600 pcsPart C = 1650 pcs# of shifts =發(fā)運(yùn)總裝焊接沖壓Takt =C.T. =D.T. =FTQ = 90%C/O Time =Lot Size =# of ShiftsWIP = 550 pcs.Takt =C.T. =D.T. = 20%FTQ =C/O Time =Lot Size =# of ShiftsWIP = 60 p

23、cs.Takt =C.T. =D.T. = FTQ =C/O Time = 4 hrs.Lot Size =# of ShiftsWIP = 25 pcs. 換型 停機(jī)時(shí)間一次質(zhì)量IIII2 x/day2 x/week 供應(yīng)商1,200 pcs1,500 pcs800 pcs500 pcsPC & LWeekly Build ScheduleDaily Ship Schedule6 week rolling forecast6 week rolling forecastWeekly OrderWeekly Order.27 days.17 days.4 days.5 days1.0 days.

24、18 days.02 days.008 daysTPc/t = 2.5 days現(xiàn)在狀態(tài)的繪制的步驟香港現(xiàn)代俊銘企管HK Modern JunMing Enterprise Management專業(yè) 用心 服務(wù)Professional Canniness Service17步驟 8: 具體的實(shí)施措施u在價(jià)值流圖上用通用的圖標(biāo)繪制 u在另外的紙上參考價(jià)值流和/或流程圖詳細(xì)列出行動(dòng)計(jì)劃IDiesDie RoomReceivingDie RoomShipping(Remove fromScheduleBoard)Die BenchIDies2 shifts12 shiftsSchedule Boar

25、d(Forecast)Fork TruckPress Room現(xiàn)在狀態(tài)的繪制的步驟香港現(xiàn)代俊銘企管HK Modern JunMing Enterprise Management專業(yè) 用心 服務(wù)Professional Canniness Service18FIFOSupermarket超市Signal Kanban信號(hào)看板WithdrawalKanban取料看板ProductionKanban生產(chǎn)看板Leveling均衡Physical Pull物理拉動(dòng)Kanbanarrivingin batches批量達(dá)到的看板KanbanPath看板路線KanbanPost先進(jìn)先出流程最多50件過(guò)程改進(jìn)

26、Kaizen其他的繪制圖標(biāo)香港現(xiàn)代俊銘企管HK Modern JunMing Enterprise Management專業(yè) 用心 服務(wù)Professional Canniness Service19u定義工廠未來(lái)將如何運(yùn)行u視未來(lái)狀態(tài)圖為計(jì)劃實(shí)施的藍(lán)圖設(shè)計(jì)未來(lái)狀態(tài) - 設(shè)想沒(méi)有未來(lái)狀態(tài)圖，現(xiàn)在狀態(tài)圖再好，還是沒(méi)有未來(lái)狀態(tài)圖，現(xiàn)在狀態(tài)圖再好，還是如同墻紙一樣！如同墻紙一樣！81香港現(xiàn)代俊銘企管HK Modern JunMing Enterprise Management專業(yè) 用心 服務(wù)Professional Canniness Service20步驟 1:步驟 2:步驟 3:步驟 4:步驟

27、5:步驟 6:步驟 7:驗(yàn)證客戶的需求繪制將來(lái)狀態(tài)的過(guò)程流繪制將來(lái)狀態(tài)的物料流繪制將來(lái)狀態(tài)的信息流計(jì)算產(chǎn)品總生產(chǎn)周期TPCT具體的行動(dòng)計(jì)劃規(guī)劃實(shí)施概要規(guī)劃實(shí)施概要82繪制將來(lái)狀態(tài)步驟香港現(xiàn)代俊銘企管HK Modern JunMing Enterprise Management專業(yè) 用心 服務(wù)Professional Canniness Service21初始情形Step7: 規(guī)劃實(shí)施概要將來(lái)情形Inj:Molding2SenderAssy2MSSAssyPlants7Stamping10TankAssy4Perform to TAKT & Pitch.Produce to OrderLoad Leveling and PullZone Maintenance & Fast ResponseLabelsLevelABABA. . .Stagingby Truckcardbycard(Pitch = 14 Units)1ST 2ND 3RD 4TH 1ST 2ND 3RD 4THEstablish TAK