如何繪制VSM-價(jià)值流分析圖課件

ValueStreamMappingValueStreamMappingVSM的目的ValueStreamMapping(VSM)是價(jià)值流程圖，它可以指出在進(jìn)行生產(chǎn)或服務(wù)時(shí)，還需要那些Lean工具來輔助，以及改善工作的優(yōu)先級。每一項(xiàng)VSM活動都會產(chǎn)生改善行動計(jì)劃(KaizenActionPlan)，它將根本地對質(zhì)量、交期、庫存、成本、生產(chǎn)率等產(chǎn)生大幅度的改進(jìn)。VSM的目的ValueStreamMapping(VS2什么是VSM價(jià)值流包括了完成某一種產(chǎn)品或服務(wù)由原材料開始到交貨給顧客所需要的必須的所有制程步驟，它包括加值過程和非價(jià)值過程，由物流、信息流、工藝流程和數(shù)據(jù)信息組成。什么是VSM價(jià)值流包括了完成某一種產(chǎn)品或服務(wù)由原材料開始到交3VSM能做到的和不能做到的VSM能夠指出價(jià)值流中的浪費(fèi)，并確認(rèn)出消除浪費(fèi)的改善活動。VSM本身，并不能改善價(jià)值流。VSM不能取代使我們改進(jìn)的改善活動。VSM不能取代改進(jìn)過程的領(lǐng)導(dǎo)力。VSM能做到的和不能做到的VSM能夠指出價(jià)值流中的浪費(fèi)，并確4ProductFamily產(chǎn)品族Current-statemap現(xiàn)況圖Future-statemap未來圖Implementation實(shí)現(xiàn)KaizenActionplan改善行動計(jì)劃價(jià)值流繪圖的過程步驟ProductFamilyCurrent-statema5什么是產(chǎn)品族根據(jù)戰(zhàn)略部署或者顧客的需求，來找出需要改進(jìn)的產(chǎn)品族。同一族具有相似的制程、設(shè)備和順序。產(chǎn)品族不是產(chǎn)品使用者或經(jīng)銷商所認(rèn)為的產(chǎn)品類別。不具有相同制程就不是同一個(gè)產(chǎn)品族。什么是產(chǎn)品族根據(jù)戰(zhàn)略部署或者顧客的需求，來找出需要改進(jìn)的產(chǎn)品6PQPR產(chǎn)品數(shù)量生產(chǎn)制程表一個(gè)產(chǎn)品族PQPR產(chǎn)品數(shù)量生產(chǎn)制程表一個(gè)產(chǎn)品族7現(xiàn)況圖現(xiàn)況圖是跟隨一個(gè)產(chǎn)品從結(jié)束回溯至開始的生產(chǎn)制程，并利用物流和信息流的圖標(biāo)來描繪出可目視的價(jià)值流圖?，F(xiàn)況圖現(xiàn)況圖是跟隨一個(gè)產(chǎn)品從結(jié)束回溯至開始的生產(chǎn)制程，并利用8如何繪制VSM-價(jià)值流分析圖課件9如何繪制VSM-價(jià)值流分析圖課件10如何繪制VSM-價(jià)值流分析圖課件11如何繪制VSM-價(jià)值流分析圖課件12TheBelowDataGetsAddedToOrAbovetheProcessBox下列數(shù)據(jù)記錄于制程盒內(nèi)或上方SharedResource(Sharediftheresourceisusedbyothervaluestreams)共享資源…………….SRNumberOfOperators操作員人數(shù)………………………=#NumberOfShiftsThisProcessIsRun執(zhí)行此制程的班次數(shù)………..SH=#TaktTime(Shownonetimein/nearthecustomerDataBox)客戶需求時(shí)間………T/T=TimeNote:TheFollowingInformationGoesIntheDataBoxbelowtheProcessBox下列信息記錄于制程盒下方的數(shù)據(jù)盒內(nèi)OperatorCycleTime操作員周期時(shí)間

…………………OCT=TimeMachineCycleTime機(jī)器周期時(shí)間

…………………MCT=TimeDropOffRate(Howoftenafinishedpartiscompletedofftheendoftheprocess)產(chǎn)出率

………….…...…D/R=TimeProcessLeadTime(Timerequiredtocompleteabatchthroughaprocess)制程前置時(shí)間

……PLT=TimeBatchSize(Sizeofthebatchthroughaprocesswhengreaterthanonepiece)披量

………………..…………BATCH=PiecesProcessTimePerPiece(Processlead-timedividedbybatchsize)單件制程時(shí)間

………………PTP=TimeRejectRate(Percentofproductthatisrejectedforqualitydefects)不良率

……..……..….……..REJ=%Uptime(Percentofplannedtimetheprocessruns,takesoutbreakdowns&unplannedmaintenance)可操作時(shí)率

U/T=%ChangeoverTime(TimetochangefromthelastgoodpieceofpartAtothefirstgoodpieceofpartB)換模時(shí)間C/O=TimeEveryPartEvery_____(Howofteneverypartnumberisrunthroughtheprocess,SetupWheel)生產(chǎn)循環(huán)時(shí)間

EPE=TimePitchInterval(Howoftenthecontainerquantityiscompleted)間距時(shí)間……..…...PITCH=TimeProcessBoxt制程盒NOTE: Onlyplaceappropriatedatainthedatabox. Thelistabovemaynotbetotallyinclusive.DataBox資料盒數(shù)據(jù)盒只記錄實(shí)際需要的數(shù)據(jù)，不一定要記錄上面的全部信息數(shù)據(jù)盒和制程方框的定義及符號TheBelowDataGetsAddedToO13如何繪制VSM-價(jià)值流分析圖課件14如何繪制VSM-價(jià)值流分析圖課件15如何繪制VSM-價(jià)值流分析圖課件16如何繪制VSM-價(jià)值流分析圖課件17如何繪制VSM-價(jià)值流分析圖課件18如何繪制VSM-價(jià)值流分析圖課件19如何繪制VSM-價(jià)值流分析圖課件20如何繪制VSM-價(jià)值流分析圖課件21如何繪制VSM-價(jià)值流分析圖課件22精益價(jià)值流的觀念第一個(gè)觀念：遵循值流來重新架構(gòu)組織價(jià)值流的改造是一件大工程，它是各個(gè)職能的成員組成的一個(gè)團(tuán)隊(duì)，并選出一個(gè)合適的Leader。為了有效支持改造工作，管理方面的和實(shí)質(zhì)的資源必須步調(diào)一致，遵循價(jià)值流團(tuán)隊(duì)所設(shè)定的目標(biāo)，各成員定期向負(fù)責(zé)人匯報(bào)進(jìn)度。精益價(jià)值流的觀念第一個(gè)觀念：遵循值流來重新架構(gòu)組織23精益價(jià)值流的觀念第二個(gè)觀念：計(jì)算出客戶需求時(shí)間(Takttime)客戶需求時(shí)間(Takttime)是指為了滿足客戶需求，產(chǎn)品需要以多快的速度產(chǎn)出，它是把每天可用的工作時(shí)間除以客戶每天的需求量，所得到的計(jì)算結(jié)果。這個(gè)結(jié)果表示值流產(chǎn)出一件成品所應(yīng)該采用的生產(chǎn)步伐，它與銷售的步伐一致，因此不會有生產(chǎn)過剩的現(xiàn)象?？蛻粜枨髸r(shí)間記錄在值流圖的客戶數(shù)據(jù)盒(databox)內(nèi)。精益價(jià)值流的觀念第二個(gè)觀念：計(jì)算出客戶需求時(shí)間(Taktt24精益價(jià)值流的觀念第三個(gè)觀念：盡可能發(fā)展一件流其意義為在歷經(jīng)的多個(gè)步驟中，一次只生產(chǎn)一件，讓每個(gè)步驟之間不會產(chǎn)生停滯。一件流的表示方法就是在執(zhí)行一件流的地方劃一個(gè)程序盒(processbox)。當(dāng)不同的程序以一件流連接時(shí)，這些程序應(yīng)該合并為一個(gè)程序盒。精益價(jià)值流的觀念第三個(gè)觀念：盡可能發(fā)展一件流25OneperDayDon’tProduce7unitsonceperweekwhenthecustomerwants1perday.當(dāng)顧客一天需要一部時(shí)，不要一星期一次給七部1Day1DayTaktTime=1Day客戶需求時(shí)間=一天ProductionshouldbepulledalongatTakttime.Donotallowroomorcapabilityforbatching.要照著客戶需求時(shí)間來拉引，不要因?yàn)榭臻g和產(chǎn)能足夠而推擠OneDon’tProduce7unitsonce26精益價(jià)值流的觀念第四個(gè)觀念：縮短換模時(shí)間和小批量運(yùn)行縮短換模時(shí)間可以移除小批量運(yùn)行的其中一個(gè)主要障礙。如果上游程序以小批量來運(yùn)行，一旦下游的需求有變動時(shí)，可以更快速地反應(yīng)。應(yīng)該持續(xù)地努力降低為了生產(chǎn)多樣產(chǎn)品所耗費(fèi)的時(shí)間，例如：換模時(shí)間。生產(chǎn)多樣產(chǎn)品所耗費(fèi)的時(shí)間以生產(chǎn)循環(huán)時(shí)間(EPE)記錄于數(shù)據(jù)盒。精益價(jià)值流的觀念第四個(gè)觀念：縮短換模時(shí)間和小批量運(yùn)行27精益價(jià)值流的觀念第五個(gè)觀念：在無法執(zhí)行一件流的地方使用看板拉引系統(tǒng)看板拉引系統(tǒng)可以有效地將精益價(jià)值流(leanvaluestream)中不連貫的程序結(jié)合起來，可以用在一件流中斷的地方，避免超量生產(chǎn)。先進(jìn)先出FIFO(“firstin,firstout”)是另外一種程序之間移動料件的方法。精益價(jià)值流的觀念第五個(gè)觀念：在無法執(zhí)行一件流的地方使用看板拉28精益價(jià)值流的觀念第六個(gè)觀念：只對價(jià)值流中的一個(gè)制程發(fā)出生產(chǎn)排程價(jià)值流中的信息流(informationflow)可以簡化，在精益價(jià)值流中接受生產(chǎn)排程命令的程序稱為引導(dǎo)程序(pacemakerprocess)。引導(dǎo)點(diǎn)必須排除值流中其他程序的產(chǎn)能限制，來安排全部上游程序的生產(chǎn)步調(diào)。選定引導(dǎo)程序是非常重要的。精益價(jià)值流的觀念第六個(gè)觀念：只對價(jià)值流中的一個(gè)制程發(fā)出生產(chǎn)排29精益價(jià)值流的觀念第七個(gè)觀念：引導(dǎo)點(diǎn)的生產(chǎn)數(shù)量及種類平穩(wěn)化當(dāng)高批量成為常態(tài)性的生產(chǎn)模式時(shí)，會產(chǎn)生過多的浪費(fèi)，在大量庫存品的背后將隱藏嚴(yán)重的問題。批量處理也就表示上游的材料也是以批量來投入，這樣會增加在制品的庫存量，也會擴(kuò)大生產(chǎn)排程的錯(cuò)誤。利用負(fù)荷平穩(wěn)化(Loadleveling)可以很大限度的解決問題，平準(zhǔn)盒(Heijunkabox)可以協(xié)助我們將混雜產(chǎn)品及生產(chǎn)數(shù)量平穩(wěn)化。精益價(jià)值流的觀念第七個(gè)觀念：引導(dǎo)點(diǎn)的生產(chǎn)數(shù)量及種類平穩(wěn)化30平準(zhǔn)盒(Heijunkabox)Kanbanarerespondedtofromlefttorightatpitchincrement看板由左至右，依序置于相對應(yīng)的間距時(shí)間格子內(nèi)Onerow

perProduct

type一種產(chǎn)品一排

8:008:108:208:308:408:509:009:10TypeA

TypeB

TypeC

AOnecolumnperpitch.一列為一間距時(shí)間

Herepitch=10min.BCABCAB平準(zhǔn)盒(Heijunkabox)Kanbanarere31精益價(jià)值流的觀念第八個(gè)觀念：主要績效指標(biāo)(KPI)測量價(jià)值流中重要項(xiàng)目的效能是否已經(jīng)轉(zhuǎn)變?yōu)榫鎯r(jià)值流(leanvaluestream)。經(jīng)常審視整個(gè)值流中的安全(S)、質(zhì)量(Q)、交期(D)、庫存(I)、成本(C)以及生產(chǎn)率(P)等，以確認(rèn)主要績效指標(biāo)的進(jìn)度目標(biāo)是否有達(dá)到和應(yīng)該注意改善的地方。精益價(jià)值流的觀念第八個(gè)觀念：主要績效指標(biāo)(KPI)32精益價(jià)值流的觀念第九個(gè)觀念：持續(xù)改善的領(lǐng)導(dǎo)力無論價(jià)值流變成多么精益，總是還有改善的空間。每當(dāng)除去一種浪費(fèi)，另一種浪費(fèi)就很容易浮現(xiàn)出來，所有價(jià)值流的成員必須持續(xù)地消除浪費(fèi)，除非這些程序已標(biāo)準(zhǔn)化和被有效地維持，否則幾個(gè)月努力消除的浪費(fèi)又會逐漸回復(fù)并侵蝕我們的成果。精益價(jià)值流的觀念第九個(gè)觀念：持續(xù)改善的領(lǐng)導(dǎo)力33ICoils5daysI4600L2400RI1100L600ROCT=62secD/R=62secC/O=0REJ=6%U/T=100%2Shifts27,600sec.Avail.OCT=40secD/R=40secC/O=0REJ=7%U/T=100%2Shifts27,600sec.Avail.ShippingStagingIII1600L850R1200L640R2700L1440RFerrous

MetalsCo.500ftcoilsTues&ThursMachine1OCT=39secD/R=39secC/O=10minREJ=4%U/T=100%2Shifts27,600secAvail.MCT=1secondC/O=1hourREJ=3%U/T=85%27,600sec.avail.EPE=2weeksStamp200tWeld1OCT=46secD/R=46secC/O=10minREJ=5%U/T=80%2Shifts27,600sec.Avail.1xdailySub-Assembly1Assembly1MRP18,400pcs/mo-12,000“L”-6,400“R”Tray=20pcs2ShiftsHighlandManufacturingSheetMetalHousingsCurrentState(Date)DailyShip

ScheduleWeeklyScheduleTT=60sec.Manchester

Avenue6-week

ForecastWeekly

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ControlMRP90/60/30day

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Order5days7.6days 1.8days2.7days2days4.5days 1sec.39sec.46sec.62sec.40sec.LeadTime=

23.6daysProcessTime=

188secWhatisTaktTime?客戶需求時(shí)間是多少？ICoilsI4600LI1100LOCT=62s34ICoils5daysI4600L2400RI1100L600ROCT=62secD/R=62secC/O=0REJ=6%U/T=100%2Shifts27,600sec.Avail.OCT=40secD/R=40secC/O=0REJ=7%U/T=100%2Shifts27,600sec.Avail.ShippingStagingIII1600L850R1200L640R2700L1440RFerrous

MetalsCo.500ftcoilsTues&ThursMachine1OCT=39secD/R=39secC/O=10minREJ=4%U/T=100%2Shifts27,600secAvail.MCT=1secondC/O=1hourREJ=3%U/T=85%27,600sec.avail.EPE=2weeksStamp200tWeld1OCT=46secD/R=46secC/O=10minREJ=5%U/T=80%2Shifts27,600sec.Avail.1xdailySub-Assembly1Assembly1MRP18,400pcs/mo-12,000“L”-6,400“R”Tray=20pcs2ShiftsHighlandManufacturingSheetMetalHousingsCurrentState(Date)DailyShip

ScheduleWeeklyScheduleTT=60sec.Manchester

Avenue6-week

ForecastWeekly

faxProduction

ControlMRP90/60/30day

ForecastsDaily

Order5days7.6days 1.8days2.7days2days4.5days 1sec.39sec.46sec.62sec.40sec.LeadTime=

23.6daysProcessTime=

188sec2.Willyoubuildtoafinishedgoods

supermarketordirectlytocustomerorder?價(jià)值流是到成品超市為止，還是到顧客訂單？ICoilsI4600LI1100LOCT=62s350s39s46s62s40sTakttime60secondsStampMachineWeldSub-assyAssy(auto-feed)3.Wherecanone-pieceflowbe

implemented?Thestampingpress?那里可以執(zhí)行一件流？在沖壓制程？No–whynot?不行-為何不行？0s39s46s62s40sTakttimeStamp36ICoils5daysI4600L2400RI1100L600ROCT=62secD/R=62secC/O=0REJ=6%U/T=100%2Shifts27,600sec.Avail.OCT=40secD/R=40secC/O=0REJ=7%U/T=100%2Shifts27,600sec.Avail.ShippingStagingIII1600L850R1200L640R2700L1440RFerrous

MetalsCo.500ftcoilsTues&ThursMachine1OCT=39secD/R=39secC/O=10minREJ=4%U/T=100%2Shifts27,600secAvail.MCT=1secondC/O=1hourREJ=3%U/T=85%27,600sec.avail.EPE=2weeksStamp200tWeld1OCT=46secD/R=46secC/O=10minREJ=5%U/T=80%2Shifts27,600sec.Avail.1xdailySub-Assembly1Assembly1MRP18,400pcs/mo-12,000“L”-6,400“R”Tray=20pcs2ShiftsHighlandManufacturingSheetMetalHousingsCurrentState(Date)DailyShip

ScheduleWeeklyScheduleTT=60sec.Manchester

Avenue6-week

ForecastWeekly

faxProduction

ControlMRP90/60/30day

ForecastsDaily

Order5days7.6days 1.8days2.7days2days4.5days 1sec.39sec.46sec.62sec.40sec.LeadTime=

23.6daysProcessTime=

188sec4.Whatisthepacemakerprocess?引導(dǎo)制程在那里？ICoilsI4600LI1100LOCT=62s37ICoils5daysI4600L2400RI1100L600ROCT=62secD/R=62secC/O=0REJ=6%U/T=100%2Shifts27,600sec.Avail.OCT=40secD/R=40secC/O=0REJ=7%U/T=100%2Shifts27,600sec.Avail.ShippingStagingIII1600L850R1200L640R2700L1440RFerrous

MetalsCo.500ftcoilsTues&ThursMachine1OCT=39secD/R=39secC/O=10minREJ=4%U/T=100%2Shifts27,600secAvail.MCT=1secondC/O=1hourREJ=3%U/T=85%27,600sec.avail.EPE=2weeksStamp200tWeld1OCT=46secD/R=46secC/O=10minREJ=5%U/T=80%2Shifts27,600sec.Avail.1xdailySub-Assembly1Assembly1MRP18,400pcs/mo-12,000“L”-6,400“R”Tray=20pcs2ShiftsHighlandManufacturingSheetMetalHousingsCurrentState(Date)DailyShip

ScheduleWeeklyScheduleTT=60sec.Manchester

Avenue6-week

ForecastWeekly

faxProduction

ControlMRP90/60/30day

ForecastsDaily

Order5days7.6days 1.8days2.7days2days4.5days 1sec.39sec.46sec.62sec.40sec.LeadTime=

23.6daysProcessTime=

188sec5.Whatpullsystemswillbeused

betweendisconnectedprocesses?不連貫制程可以使用何種拉引系統(tǒng)？Whatwillthissupermarketeliminate?這個(gè)超市可以消除什么？ICoilsI4600LI1100LOCT=62s380s39s46s62s40sTakttime60secondsStampMachineWeldSub-assyAssy(auto-feed)Whereelsecanone-pieceflowbe

implemented?Themachineandweldprocesses?還有別的地方可執(zhí)行一件流嗎？是車削和焊接制程嗎？Yes!就是這里0s39s46s62s40sTakttimeStamp39ICoils5daysI4600L2400RI1100L600ROCT=62secD/R=62secC/O=0REJ=6%U/T=100%2Shifts27,600sec.Avail.OCT=40secD/R=40secC/O=0REJ=7%U/T=100%2Shifts27,600sec.Avail.ShippingStagingIII1600L850R1200L640R2700L1440RFerrous

MetalsCo.500ftcoilsTues&ThursMachine1OCT=39secD/R=39secC/O=10minREJ=4%U/T=100%2Shifts27,600secAvail.MCT=1secondC/O=1hourREJ=3%U/T=85%27,600sec.avail.EPE=2weeksStamp200tWeld1OCT=46secD/R=46secC/O=10minREJ=5%U/T=80%2Shifts27,600sec.Avail.1xdailySub-Assembly1Assembly1MRP18,400pcs/mo-12,000“L”-6,400“R”Tray=20pcs2ShiftsHighlandManufacturingSheetMetalHousingsCurrentState(Date)DailyShip

ScheduleWeeklyScheduleTT=60sec.Manchester

Avenue6-week

ForecastWeekly

faxProduction

ControlMRP90/60/30day

ForecastsDaily

Order5days7.6days 1.8days2.7days2days4.5days 1sec.39sec.46sec.62sec.40sec.LeadTime=

23.6daysProcessTime=

188secWhereelsecanone-pieceflowbe

implemented?還有別的地方可執(zhí)行一件嗎？Byestablishing

one-pieceflow

here,whatgoesaway?這里用一件流，什么會消失？VRKICoilsI4600LI1100LOCT=62s400s39s46s62s40sTakttime60secondsStampMachineWeldSub-assyAssy(auto-feed)Whereelsecanone-pieceflowbe

implemented?Theassemblyprocesses?還有別的地方可執(zhí)行一件流嗎？是組裝制程嗎？Yes!正是0s39s46s62s40sTakttimeStamp41ICoils5daysI4600L2400RI1100L600ROCT=62secD/R=62secC/O=0REJ=6%U/T=100%2Shifts27,600sec.Avail.OCT=40secD/R=40secC/O=0REJ=7%U/T=100%2Shifts27,600sec.Avail.ShippingStagingIII1600L850R1200L640R2700L1440RFerrous

MetalsCo.500ftcoilsTues&ThursMachine1OCT=39secD/R=39secC/O=10minREJ=4%U/T=100%2Shifts27,600secAvail.MCT=1secondC/O=1hourREJ=3%U/T=85%27,600sec.avail.EPE=2weeksStamp200tWeld1OCT=46secD/R=46secC/O=10minREJ=5%U/T=80%2Shifts27,600sec.Avail.1xdailySub-Assembly1Assembly1MRP18,400pcs/mo-12,000“L”-6,400“R”Tray=20pcs2ShiftsHighlandManufacturingSheetMetalHousingsCurrentState(Date)DailyShip

ScheduleWeeklyScheduleTT=60sec.Manchester

Avenue6-week

ForecastWeekly

faxProduction

ControlMRP90/60/30day

ForecastsDaily

Order5days7.6days 1.8days2.7days2days4.5days

1sec.39sec.46sec.62sec.40sec.LeadTime=

23.6daysProcessTime=

188secWhereelsecanone-pieceflowbe

implemented?Theassemblyprocesses?還有別的地方可執(zhí)行一件流嗎？是組裝制程嗎？Byestablishing

one-pieceflow

here,whatgoesaway?這里用一件流，什么會消失？VRKICoilsI4600LI1100LOCT=62s42187secondswork=3.1operators60secondsTAKT =4operators = 3operators (target)Whereelsecanone-pieceflowbe

implemented?Let’slookatOCTtoevaluate:還有別的地方可執(zhí)行一件流嗎？看看操作員周期時(shí)間？5days7.6days 1.8days2.7days2days4.5days

1sec.39sec.46sec.62sec.40sec.MCTOCTOCTOCTOCTWhatisthetotalhuman

workcontenttomachine,weld

andassembleonehousing?完成一件的總?cè)斯r(shí)間是多久？39+46+62+40=187secondsButcustomerneedsahousing

every60seconds但是顧客每60秒需要一件Moreimportanttoassign4thoperatorto

othermeaningfulwork第四位操作員做其它有意義的工作比較重要187secondswork=3.1opera43Takttime60secondsMachineWeldWeldSub-AssemblyAssembly60secs.60secs.54secs.58x3=174secondsHighlandOperatorLoadingChartFuture-State未來狀態(tài)的操作員負(fù)荷表TakttimeMachineWeldWeld44ICoils5daysI4600L2400RI1100L600ROCT=62secD/R=62secC/O=0REJ=6%U/T=100%2Shifts27,600sec.Avail.OCT=40secD/R=40secC/O=0REJ=7%U/T=100%2Shifts27,600sec.Avail.ShippingStagingIII1600L850R1200L640R2700L1440RFerrous

MetalsCo.500ftcoilsTues&ThursMachine1OCT=39secD/R=39secC/O=10minREJ=4%U/T=100%2Shifts27,600secAvail.MCT=1secondC/O=1hourREJ=3%U/T=85%27,600sec.avail.EPE=2weeksStamp200tWeld1OCT=46secD/R=46secC/O=10minREJ=5%U/T=80%2Shifts27,600sec.Avail.1xdailySub-Assembly1Assembly1MRP18,400pcs/mo-12,000“L”-6,400“R”Tray=20pcs2ShiftsHighlandManufacturingSheetMetalHousingsCurrentState(Date)DailyShip

ScheduleWeeklyScheduleTT=60sec.Manchester

Avenue6-week

ForecastWeekly

faxProduction

ControlMRP90/60/30day

ForecastsDaily

Order5days7.6days 1.8days2.7days2days4.5days

1sec.39sec.46sec.62sec.40sec.LeadTime=

23.6daysProcessTime=

188secWhereelsecanone-pieceflowbe

implementednowthatwehavelookedatOCT?看過操作員周期時(shí)間后，還有別的地方可執(zhí)行一件流嗎？Byestablishing

one-pieceflow

here,whatgoesaway?這里用一件流，什么會消失？VRKSTDWK38%Prod.ImpSMED<10min.ICoilsI4600LI1100LOCT=62s45StampShippingHousingCell1xdailyFerrousMetalsCo.Tues&Thurs18,400pcs/mo-12,000“L”-6,400“R”.Tray=20pcs2shiftsOCT=174sec.D/R=58sec.MCT=75sec.C/O=57secs.Rej=1%U/T=80%MCT=1sec.C/O=1hourRej=1%U/T=85%500ftcoils2daysTakt=460min.460pcs.=60secPitch=60sec.X20pcs.=20minHighlandManufacturingHousingsFutureState(Date)Manchester

AvenueDailyShip

Schedule920pcs/dayICoils5daysVRKUT

>95%STDWK38%Prod.ImpSMED<10min6-week

ForecastWeekly

faxProduction

ControlMRP90/60/30day

ForecastsDaily

OrderHereiswhatourFuture-Statemapnowlookslikesofar…這是到目前為止，未來圖看起來的樣子StampShippingHousingCell1xFer46StampShippingHousingCell1xdailyFerrousMetalsCo.Tues&Thurs18,400pcs/mo-12,000“L”-6,400“R”.Tray=20pcs2shiftsOCT=174sec.D/R=58sec.MCT=75sec.C/O=57secs.Rej=1%U/T=80%MCT=1sec.C/O=1hourRej=1%U/T=85%500ftcoils2daysTakt=460min.460pcs.=60secPitch=60sec.X20pcs.=20minHighlandManufacturingHousingsFutureState(Date)Manchester

AvenueDailyShip

Schedule920pcs/dayICoils5daysVRKUT

>95%STDWK38%Prod.ImpSMED<10min6-week

ForecastWeekly

faxProduction

ControlMRP90/60/30day

ForecastsDaily

Order605.Whatpullsystemswillbeusedbetween

disconnectedprocesses?ExamineStampingPull中斷的制程之間使用何種拉引系統(tǒng)？試試沖壓制程的拉引StampShippingHousingCell1xFer47StampShippingHousingCell1xdailyFerrousMetalsCo.Tues&Thurs18,400pcs/mo-12,000“L”-6,400“R”.Tray=20pcs2shiftsOCT=174sec.D/R=58sec.MCT=75sec.C/O=57secs.Rej=1%U/T=80%MCT=1sec.C/O=1hourRej=1%U/T=85%500ftcoils2daysTakt=460min.460pcs.=60secPitch=60sec.X20pcs.=20minHighlandManufacturingHousingsFutureState(Date)Manchester

AvenueDailyShip

Schedule920pcs/dayICoils5daysVRKUT

>95%STDWK38%Prod.ImpSMED<10min6-week

ForecastWeekly

faxProduction

ControlMRP90/60/30day

ForecastsDaily

Order60Nowthatthewithdrawalkanbanisplace,how

willtheproductionkanbaninStampwork?若運(yùn)輸看板已被提取，沖壓工作的生產(chǎn)看板將會如何？60StampShippingHousingCell1xFer48StampShippingHousingCell1xdailyFerrousMetalsCo.Tues&Thurs18,400pcs/mo-12,000“L”-6,400“R”.Tray=20pcs2shiftsOCT=174sec.D/R=58sec.MCT=75sec.C/O=57secs.Rej=1%U/T=80%MCT=1sec.C/O=1hourRej=1%U/T=85%500ftcoils2daysTakt=460min.460pcs.=60secPitch=60sec.X20pcs.=20minHighlandManufacturingHousingsFutureState(Date)Manchester

AvenueDailyShip

Schedule920pcs/dayICoils5daysVRKUT

>95%STDWK38%Prod.ImpSMED<10min6-week

ForecastWeekly

faxProduction

ControlMRP90/60/30day

ForecastsDaily

Order60Whywon’tthepullsystemwe’vedesigned

workhere?為何不在此處使用拉引系統(tǒng)？Becauseof

the1hour

changeover!因?yàn)閾Q模時(shí)間要一小時(shí)60StampShippingHousingCell1xFer49StampShippingHousingCell1xdailyFerrousMetalsCo.Tues&Thurs18,400pcs/mo-12,000“L”-6,400“R”.Tray=20pcs2shiftsOCT=174sec.D/R=58sec.MCT=75sec.C/O=57secs.Rej=1%U/T=80%MCT=1sec.C/O=1hourRej=1%U/T=85%500ftcoils2daysTakt=460min.460pcs.=60secPitch=60sec.X20pcs.=20minHighlandManufacturingHousingsFutureState(Date)Manchester

AvenueDailyShip

Schedule920pcs/dayICoils5daysVRKUT

>95%STDWK38%Prod.ImpSMED<10min6-week

ForecastWeekly

faxProduction

ControlMRP90/60/30day

ForecastsDaily

Order60Wewillneedtouseasignalkanbanfor

batchprocessesthathavechangeovertimes對于換模時(shí)間較長的批量制程，必須使用訊號看板batchStampShippingHousingCell1xFer50StampShippingHousingCell1xdailyFerrousMetalsCo.Tues&Thurs18,400pcs/mo-12,000“L”-6,400“R”.Tray=20pcs2shiftsOCT=174sec.D/R=58sec.MCT=75sec.C/O=57secs.Rej=1%U/T=80%MCT=1sec.C/O=1hourRej=1%U/T=85%500ftcoils2daysTakt=460min.460pcs.=60secPitch=60sec.X20pcs.=20minHighlandManufacturingHousingsFutureState(Date)Manchester

AvenueDailyShip

Schedule920pcs/dayICoils5daysVRKUT

>95%STDWK38%Prod.ImpSMED<10min6-week

ForecastWeekly

faxProduction

ControlMRP90/60/30day

ForecastsDaily

Order60Howdowedeterminethebatchsize?如何決定批量的大小？batch1.5daysStampShippingHousingCell1xFer51StampShippingHousingCell1xdailyFerrousMetalsCo.Tues&Thurs18,400pcs/mo-12,000“L”-6,400“R”.Tray=20pcs2shiftsOCT=174sec.D/R=58sec.MCT=75sec.C/O=57secs.Rej=1%U/T=80%MCT=1sec.C/O=1hourRej=1%U/T=85%500ftcoils2daysTakt=460min.460pcs.=60secPitch=60sec.X20pcs.=20minHighlandManufacturingHousingsFutureState(Date)Manchester

AvenueDailyShip

Schedule920pcs/dayICoils5daysVRKUT

>95%STDWK38%Prod.ImpSMED<10min6-week

ForecastWeekly

faxProduction

ControlMRP90/60/30day

ForecastsDaily

Order60batch1.5days6.Howwillproductionbescheduledand

withdrawnatthepacemakertocreatelevel

volumeandmix?為了平穩(wěn)化和混合生產(chǎn)，在引導(dǎo)點(diǎn)該如何做生產(chǎn)排程和提取？46

trays20stageStampShippingHousingCell1xFer52StampShippingHousingCell1xdailyFerrousMetalsCo.Tues&Thurs18,400pcs/mo-12,000“L”-6,400“R”.Tray=20pcs2shiftsOCT=174sec.D/R=58sec.MCT=75sec.C/O=57secs.Rej=1%U/T=80%MCT=1sec.C/O=1hourRej=1%U/T=85%500ftcoils2daysTakt=460min.460pcs.=60secPitch=60sec.X20pcs.=20minHighlandManufacturingHousingsFutureState(Date)Manchester

AvenueDailyShip

Schedule920pcs/dayICoils5daysVRKUT

>95%STDWK38%Prod.ImpSMED<10min6-week

ForecastWeekly

faxProduction

ControlMRP90/60/30day

ForecastsDaily

Order60batch1.5days6.Howwillproductionbescheduledand

withdrawnatthepacemakertocreatelevel

volumeandmix?為了平穩(wěn)化和混合生產(chǎn)，在引導(dǎo)點(diǎn)該如何做生產(chǎn)排程和提??？46

traysstage34200X0X2012RLLRLL…pitch=20min.StampShippingHousingCell1xFer53StampShippingHousingCell1xdailyFerrousMetalsCo.18,400pcs/mo-12,000“L”-6,400“R”.Tray=20pcs2shiftsOCT=174sec.D/R=58sec.MCT=75sec.C/O=57secs.Rej=1%U/T=80%MCT=1sec.C/O=1hourRej=1%U/T=85%500ftcoils2daysTakt=460min.460pcs.=60secPitch=60sec.X20pcs.=20minHighlandManufacturingHousingsFutureState(Date)Manchester

AvenueDailyShip

Schedule920pcs/dayVRKUT

>95%STDWK38%Prod.ImpSMED<10min6-week

ForecastWeekly

faxProduction

ControlMRP90/60/30day

ForecastsDaily

Order60batch1.5daysWherecanHighlanduseonemoresupermarket

inthisdoor-to-doorvaluestream?逐一檢討什么地方可以再建立一個(gè)超市？46

traysstage0X0X20123420RLLRLL…pitch=20min.Daily1.5daysCoilDailyICoils5daysStampShippingHousingCell1xFer54StampShippingHousingCell1xdailyFerrousMetalsCo.18,400pcs/mo-12,000“L”-6,400“R”.Tray=20pcs2shiftsOCT=174sec.D/R=58sec.MCT=75sec.C/O=57secs.Rej=1%U/T=80%MCT=1sec.C/O=1hourRej=1%U/T=85%500ftcoils2daysTakt=460min.460pcs.=60secPitch=60sec.X20pcs.=20minHighlandManufacturingHousingsFutureState(Date)Manchester

AvenueDailyShip

Schedule920pcs/dayVRKUT

>95%STDWK38%Prod.ImpSMED<10min6-week

ForecastWeekly

faxProduction

ControlMRP90/60/30day

ForecastsDaily

Order60batch1.5days46

traysstage0X0X20123420RLLRLL…pitch=20min.Daily1.5daysCoilDailyWenolonger

needMRPto

control

production不再需要用物料需求計(jì)劃來管制生產(chǎn)1.5days1sec.174sec2days1.5daysLeadTimeProcessTime=5days=175sec.StampShippingHousingCell1xFer55StampHousingCellManchester

Avenue1xdailyShippingStageFerrousMetalsCo.ProductionControl6-weekForecastDailyOrderDaily(milkrun)Coils1.5days20batch60COIL2020200X0XDailyShipSchedule90/60/30day

ForecastsDailyOrder1.5days1sec.1.5days174sec2daysLeadTime

Process

Time=5days=175sec.SMEDVRK

U/T>95%HighlandFutureStateMapMRP4046Trays1.5days2daysRLLRLL…

pitch=20min.18,400pcs/mo-12,000“L”-6,400“R”.Tray=20pcs2shifts920pcs/dayTakt=460min=60sec

460pcs.Pitch=60secx20pcs=20min1234OCT=174sec.D/R=58sec.MCT=75sec.C/O=57secs.Rej=1%U/T=80%.MCT=1sec.C/O=1hourRej=1%U/T=85%STDWK38%Prod.ImpHighlandManufacturingHousingsFutureState(Date)DMPSMEDDMPDMP7.WhataretheKaizenevents,projects,andDBS

Toolsthatareneededtoimplementthe

future-state?需要何種改善活動、項(xiàng)目和DBS工具來達(dá)成未來狀態(tài)？StampHousingCellManchester

Av56StampHousingCellManchester

Avenue1xdailyShippingStagingFerrousMetalsCo.ProductionControl6-weekForecastDailyOrderDaily(milkrun)Coils1.5days20batch60COIL2020200X0XDailyShipSchedule90/60/30day

ForecastsDailyOrder1.5days1sec.1.5days174sec2daysLeadTime

Process

Time=4.5days=175sec.SMEDVRK

U/T>95%HighlandFutureStateMapMRP4046Trays1.5days2daysRLLRLL…

pitch=20min.18,400pcs/mo-12,000“L”-6,400“R”.Tray=20pcs2shifts920pcs/dayTakt=460min=60sec

460pcs.Pitch=60secx20pcs=20min1234OCT=174sec.D/R=58sec.MCT=75sec.C/O=57secs.Rej=1%U/T=80%MCT=1sec.C/O=1hourRej=1%U/T=85%STDWK38%Prod.ImpHighlandManufacturingHousingsFutureState(Date)DMPSMEDDMPDMPS