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1、Value Stream MappingValue Stream Mapping Nypros HVSCapperFillingHVS IssuesABC Corp.XYZ Corp._/wk_/wkToo Much CCCCToo Little CCCCPackagingProcess-Level MappingFunction-Level MappingTask-Level MappingThe Value Stream System-Level MappingIf we want to eliminate waste from our system, we must first be a

2、ble to find it. One of the best ways to find the waste is with a process known as Value Stream Mapping.Value Stream MappingTotal Value StreamValue Stream Mapping is a collection of tools that helps you see and understand the flow of activities, material and information as a product makes its way thr

3、ough the Value Stream.What is Value Stream Mapping?Finished ProductRawMaterialsLevels of mapping the value stream for a product familySystemFunctionProcessTasksSub-TasksBegin hereValue Stream Mapping LevelsDemand Chain AnalysisSystem-Level MapsConsumerTier CTier ATier 0BottlingPlantTier 3FarmerBarre

4、l ManufacturerTier 2Tier 1BottleManufacturingSpiritDistillationPackagingSub-AssemblyTier BWholesalerRetailerGrain SupplierRestaurant1xDailyProduction ControlMRP3 monthForecastWeekly updateDaily Ship ScheduleState StreetDistributor18,400 cases/mo- 12,000 “SC”- 6,400 “US”Case = 12 bottles2 ShiftsC/T =

5、 210 BPMC/O = 30 minUptime = 85% 27,000 sec. avail.EPE = 1 weekC/T = 240 BPMC/O = 3 minUptime = 100%1 Shift 27,000 sec. avail.C/T = 300 BPMC/O = 10 minUptime = 80%1 Shift 27,000 sec. avail.C/T = 200 BPMC/O = 3 minUptime = 100%1 Shift 27,000 sec. avail.C/T = 300 BPMC/O = 30 secUptime = 100%1 Shift 27

6、,000 sec. avail.IBottles5 daysI100 SCI100 SCI75 SCI300 SCI425K SCCapperLabelerNeck BanderCase LabelerShippingFillerTues. +ThursABC Glass40K CasesWeekly SchedulePerformance BoardsQCStandardsStandardsStandardsStandardsStandardsDNypro Sales ForecastWeeklyOrderDaily Hot Orders1111Bottling ProcessProcess

7、-Level MapGENERALMATERIAL FLOWProcess/DepartmentData BoxMovement of Production MaterialsInventoryI300 pieces1 dayC/T = 45secC/O = 30min3 shifts2% ScrapAssemblyAssemblyI300 pieces1 dayProcess-Level IconsINFORMATION FLOWElectronic Information FlowManual Information FlowIMPROVEMENTDStandardsError Proof

8、ingProduct & Process Std.DStandardsProcess-Level IconsGeneral Icons1. Process/Department2. Outside Sources3. Data BoxMachiningXYZCustomerC/T = 45secC/O = 30min3 shifts2% ScrapProduction SchedulingAutomatedKPC = TasteKCC = Temp.Process Stds.Product SpecsABCSupplier14. PeopleMaterial Flow Icons1. Push

9、 Movement of production material2. Pull Movement of production materials and finished goods4. Material queue (implies where material will be pulled)FIFO3. Automated Movement of production material5. Rail Shipment6. Truck shipmentMon.+ Wed.ABC9. Market Place10. Buffer/emergency stock8. InventoryI300

10、pieces1 day7. Air shipmentMaterial Flow Icons1. Manual information flow2. Electronic information flow3. Information DescriptionWeekly ScheduleInformation Flow IconsConstraintOperationProcessBoardsDVPerformance BoardsStretchQCStandardsImprovementImprovement IconsMapping Begins with the Customer Requi

11、rementsState StreetDistributor18,400 cases/mo- 12,000 “OF”- 6,400 “WR”Case = 12 bottles2 ShiftsFirst View of the Value Stream MapC/T = 210 BPMC/O = 4 minUptime = 85% 27,000 sec. avail.EPE = 2 weeksC/T = 240 BPMC/O = 3 minUptime = 100%1 Shift 27,000 sec. avail.C/T = 300 BPMC/O = 2 minUptime = 80%1 Sh

12、ift 27,000 sec. avail.C/T = 200 BPMC/O = 2 minUptime = 100%1 Shift 27,000 sec. avail.C/T = 300 BPMC/O = 1 minUptime = 100%1 Shift 27,000 sec. avail.IBottles5 daysI100 OF75 WRI100 OF75 WRI75 OF50 WRI300 OF150 WRI2700 OF1440 WRCapperLabelerNeck BanderCase LabelerShippingFillerProcesses, Data Boxes,and

13、 Inventory TrianglesState StreetDistributor18,400 cases/mo- 12,000 “OF”- 6,400 “WR”Case = 12 bottles2 ShiftsSecond View of the Value Stream MapMaterial Flow Icons1xDailyTues. +ThursABC Glass40K CasesState StreetDistributor18,400 cases/mo- 12,000 “SC”- 6,400 “US”Case = 12 bottles2 ShiftsC/T = 210 BPM

14、C/O = 4 minUptime = 85% 27,000 sec. avail.EPE = 2 weeksC/T = 240 BPMC/O = 3 minUptime = 100%1 Shift 27,000 sec. avail.C/T = 300 BPMC/O = 2 minUptime = 80%1 Shift 27,000 sec. avail.C/T = 200 BPMC/O = 2 minUptime = 100%1 Shift 27,000 sec. avail.C/T = 300 BPMC/O = 1 minUptime = 100%1 Shift 27,000 sec.

15、avail.IBottles5 daysI100 SCI100 SCI75 SCI300 SCI425k SCCapperLabelerNeck BanderCase LabelerShippingFiller1111Third View: Process-Level Map1xDailyProduction ControlMRP3 monthForecastweeklyfaxInformation Flow and Push ArrowsC/T = 210 BPMC/O = 4 minUptime = 85% 27,000 sec. avail.EPE = 2 weeksC/T = 240

16、BPMC/O = 3 minUptime = 100%1 Shift 27,000 sec. avail.C/T = 300 BPMC/O = 2 minUptime = 80%1 Shift 27,000 sec. avail.C/T = 200 BPMC/O = 2 minUptime = 100%1 Shift 27,000 sec. avail.C/T = 300 BPMC/O = 1 minUptime = 100%1 Shift 27,000 sec. avail.IBottles5 daysI100 SCI100 SCI75 SCI300 SCI425k SCCapperLabe

17、lerNeck BanderCase LabelerShippingFillerTues. +ThursABC Glass40K CasesState StreetDistributor18,400 cases/mo- 12,000 “SC”- 6,400 “US”Case = 12 bottles2 ShiftsWeekly ScheduleDaily Ship ScheduleSales ForecastWeeklyOrderDaily Hot Orders1111Fourth View: Process-Level Map1xDailyProduction ControlMRP3 mon

18、thForecastWeekly update5 days.28 second25 sec.25 seconds20 sec.2 seconds22.5 sec.3 seconds40 sec.2 seconds2 daysProductionLead TimeValue-Added Time = 7.0 days = 1.23 sec.State StreetDistributor18,400 cases/mo- 12,000 “SC”- 6,400 “US”Case = 12 bottles2 ShiftsC/T = 210 BPMC/O = 30 minUptime = 85% 27,0

19、00 sec. avail.EPE = 1 weekC/T = 240 BPMC/O = 3 minUptime = 100%1 Shift 27,000 sec. avail.C/T = 300 BPMC/O = 10 minUptime = 80%1 Shift 27,000 sec. avail.C/T = 200 BPMC/O = 3 minUptime = 100%1 Shift 27,000 sec. avail.C/T = 300 BPMC/O = 30 secUptime = 100%1 Shift 27,000 sec. avail.IBottles5 daysI100 SC

20、I100 SCI75 SCI300 SCI425K SCCapperLabelerNeck BanderCase LabelerShippingFillerTues. +ThursABC Glass40K CasesLead Time Bars & DataWeekly ScheduleQCStandardsStandardsStandardsStandardsStandardsDBFDC Sales ForecastWeeklyOrderDaily Hot OrdersDaily Ship SchedulePerformance Boards1111Sixth View: Process-L

21、evel MapLets Review Function Level MapsSystemFunctionProcessTasksSub-TasksWe Are HereValue Stream Mapping Levels - FunctionDebarking ProcessFunction-Level Map: Log Debarking2 d15 m5 m20 m10 s90 s1 s20 s20 mEnd of ShiftSTART / STOPCOMPUTER STORAGEMULTI-DOCUMENTDECISIONOPERATIONDOCUMENTFunction-Level IconsINSPECTIONSTORAGE/DELAYOFF PAGE CONN

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