價(jià)值流圖分析

ValueStreamMapping

價(jià)值流圖析PartI:CurrentStateMapping第一部分：現(xiàn)狀圖ProductionControlSchedulingCustomer客戶Suppliers供應(yīng)商Purchasing?Materials?Manpower?PriorityManpowerAvailableDelayMakePartsPaintDeptMaterialAvailableDelayExpediteStorageStorageNeedPartsIntroduction簡(jiǎn)介ValueStreamAnalysisisaneffectivetoolininitiatingprocessimprovements.Thetoolprovidesanoverviewofthecurrentmanufacturingoperation,notingconstraintsandareasofconcern.Itprovidesforasystem-wideapproachtoidentifyingareasthatneedattentionanddevelopingplansforthateffort.在改善初期，價(jià)值流分析是一個(gè)有效的工具。這個(gè)工具供應(yīng)了當(dāng)前制造過(guò)程的總的看法，注釋了瓶頸和涉及到的區(qū)域。它供應(yīng)了一種系統(tǒng)化的途徑,來(lái)區(qū)分須要留意的地方,以及為此努力而制定的支配.VSAProcessMappingBenefits

過(guò)程圖的優(yōu)點(diǎn)Obtaincurrentplantoperatinginformation獲得當(dāng)前車間的業(yè)務(wù)資料Obtaincurrentmetricsinformation獲得當(dāng)前的數(shù)據(jù)資料Identifiesinventoryandwhereitisstored區(qū)分在庫(kù)及其地點(diǎn)Showsmaterialflow表明原料的流淌Givesyouabaselineonwhereyouareandatooltochartyourprogressafterimplementingimprovementswithintheplant在車間內(nèi)實(shí)行改進(jìn)后，給你一個(gè)繪制你進(jìn)步的基點(diǎn)和工具Objectivesfor

ValueStreamAnalysis

價(jià)值流析的目標(biāo)Understandthebenefitsofprocessmapping理解過(guò)程圖的優(yōu)點(diǎn)Developaprocessmapusingicons用圖標(biāo)來(lái)繪制過(guò)程圖Understandhowtheprocessmapwillbeusedtodevelopcurrentstatebaselines,stretchobjectivesandimprovementactions理解怎樣用過(guò)程圖來(lái)發(fā)展當(dāng)前狀態(tài)基線，展望遠(yuǎn)景和改進(jìn)行為。9daysWeeklyScheduleThur.Tue/Thur2days15days3days9days9days3daysSteelSupplierMon/Wed/FriStampingHeatTreatCust.BCust.AProdContMonthlyOrderRelease3Productsdedicated7day-3shifts/weekLotProduction-1wklotsChangeovertime-4hoursTimebetweenC/O-7shiftsScrap-7%Downtime-11%“Y”Avg.strokes/hourMonthlyReq-18,000T/T=60”IC/T=360”Scrap-3%Rework-20%Downtime10%2hrsOT56pcs/m-hMonthlyReq.-18,000Prod.Timee-450’/shift2shifts@20days/monT/T=60”IC/T=240”Scrap-7%Rework-12%Foenyimr1.5%9pcs/m-hAssemblyWeldingExampleofaCurrentStateMapDefinition定義AValueStreamisthecollectionofallactivitiesrequiredtoproduceaproduct.

Thisincludesallactivities,includingthosethataddvalueandthosethatdonot.價(jià)值流是制造產(chǎn)品所必需的全部活動(dòng)的集中。這就包括了產(chǎn)生價(jià)值和不產(chǎn)生價(jià)值的全部活動(dòng)。TheBIG

Picture整體性Usingthevaluestreamanalysismeansworkingonthebigpicture,notjusttheindividualprocesses;improvingthewhole,notjustoptimizingtheparts.運(yùn)用價(jià)值流分析意味著在整體上工作，不僅僅是個(gè)別的生產(chǎn)過(guò)程；不只是優(yōu)化局部而是提高全部。OurScope我們的范圍Forthislesson,wewillbefocusingonthe“door-to-door”productionflowinsideourplant.ThatincludesReceivingandShipping.這里我們將把重點(diǎn)放在工廠車間與車間的生產(chǎn)流程上面。它包括接收和貨運(yùn)TotalValueStream價(jià)值流OurFocus重點(diǎn)Suppliers供貨商O(píng)urPlantand/orCompany車間或公司Customer顧客OurScope(cont’d)

我們的范圍（續(xù)）Asyourexperiencegrows,youcanexpandoutwardtoincludetheflowfromsupplierstocustomers.隨著閱歷的增長(zhǎng)，你能夠向外擴(kuò)展到包括從供貨商到消費(fèi)者的連續(xù)流。Likewise,oureffortswillnotgetintothedetailsofeachdepartments’specificsofoperation.同樣的，我們的重點(diǎn)不會(huì)陷入獲得每個(gè)部門(mén)具體的操作微小環(huán)節(jié)。Thisisnota

computerprocess

這不是一個(gè)運(yùn)用

計(jì)算機(jī)的過(guò)程ValueStreamMappingisapencilandpapertoolthathelpsyoutoseeandunderstandtheflowsofmaterialandinformationasaproductmakesitswaythroughthevaluestream.價(jià)值流圖是以筆和紙為工具來(lái)幫助你在產(chǎn)品通過(guò)價(jià)值流時(shí)看清和理解物料和信息的流向。Materialand

InformationFlow

材料和信息流Themovementofmaterialisusuallywhatcomestomindwhenwediscuss“productionflow”.當(dāng)我們談?wù)摦a(chǎn)品流程時(shí)，通常想到的是材料的流淌。Butthereisanotherflow-ofinformation-whichtellseachprocesswhattomakeordonext。但還有一種-信息流，它能告知你每個(gè)過(guò)程做什么和將要做什么。Youmustmapbothofthem.你必需同時(shí)圖析他們ProductionFlowinformationmaterialUsingtheMappingTool

運(yùn)用圖析工具

First,wedrawthecurrentstatemapbygatheringinformationdirectlyfromtheshopfloor.首先，我們應(yīng)運(yùn)用從車間干脆采集的信息來(lái)繪制現(xiàn)在狀態(tài)圖。ProductFamily產(chǎn)品系列CurrentStateDrawing現(xiàn)狀圖FutureStateDrawing將來(lái)圖WorkPlan支配UsingtheMappingToolFromthis,webegintodrawourideal,orimproved,operation;ourFutureStateMap.從這里我們起先畫(huà)志向和改良的操作；我們的將來(lái)狀態(tài)圖。ProductFamily產(chǎn)品系列CurrentStateDrawing現(xiàn)狀圖FutureStateDrawing未來(lái)狀態(tài)圖WorkPlan工作計(jì)劃UsingtheMappingToolThefinalstepistoimplementaplantotransitiontheplantfromthecurrentstatetothefuturestate.最終的步驟是執(zhí)行從現(xiàn)在到將來(lái)狀態(tài)工廠轉(zhuǎn)變的支配ProductFamilyCurrentStateDrawingFutureStateDrawingWorkPlanFocusononeProductFamily重點(diǎn)在一種產(chǎn)品Drawingallyourproductflowsononemapwilltoocomplicated.在一幅圖里畫(huà)出全部的產(chǎn)品太困難。ValueStreamMappingmeanswalkinganddrawingtheprocesssteps(materialandinformation)foroneproductfamilyfromdoortodoorintheplant.價(jià)值流圖析意味著從工廠的一個(gè)車間到另一個(gè)車間畫(huà)出一種產(chǎn)品的生產(chǎn)步驟。 DrawingaCurrentStateMap繪制一幅現(xiàn)狀圖

Mappingbeginsatthelevelofdoor-to-doorflowinyourplant.在你的工廠里門(mén)對(duì)門(mén)的流淌水平下起先繪圖。Processingcategoriesareidentifiedratherthanrecordingeachandeverystep.過(guò)程種類的確定遠(yuǎn)勝于每個(gè)步驟的記錄?！癈utting”,“Welding”,“Stitching”切割，焊接，縫紉。TheIconsUsed.所用圖標(biāo)Weusesymbols,oricons,torepresentprocessesandflow.我們用標(biāo)記，圖標(biāo)來(lái)代替過(guò)程和流向。AssemblyABCCorp.MovementofProductionMaterialsMovementoffinishedgoodstotheCustomerInventoryRailShipments_/wkMaterialQueue(sequenced)ConveyanceRoutePullofMaterialfromoneprocesstonext_hour_hour

TankShipment__/wkTheIconsUsed(cont’d)ElectronicInformationFlowProductionSchedule

ManualInformationFlowweeklySignalProductionCardProductionInstructionFlowIndicatespathofProductionInstructionCardIndicatespathofMaterialwithwithdrawcardSequentialProductionScheduleProductionInstructionCardMaterialWithdrawCard

MarketplaceABCBufferorEmergencyStockABCMappingTips

繪圖技巧

Collectdatafromtheactualfloor.從現(xiàn)行的工廠收集資料Walktheentiredoor-to-doorvaluestream.沿著整個(gè)門(mén)到門(mén)的價(jià)值流走。Donotrelyoninformationthatyoudonotobtainyourself.不要依靠不是你親自得到的信息。Evenifseveralpeopleareinvolved,mapthewholevaluestreamyourself.盡管有很多人參與，你還是要自己繪制整個(gè)價(jià)值流。Resistthetemptationtouseacomputer.抵制住計(jì)算機(jī)的誘惑DrawingtheCurrentStateMap繪制現(xiàn)狀圖AnExample:一個(gè)實(shí)例：AcmeManufacturingproduceswidgets.Thewidgetsareproducedintwoversions:style-type“A”andstyle-type“B”.TheAstylehasaleft-handmountingbracketandtheBstylehasright-handmountingbracket.Thereisnovariabilityinthedesignbeyondtheversionsofthemountingbracket.阿克米加工廠生產(chǎn)以中小部件。有兩種型號(hào)：A和B型。A型有一個(gè)左側(cè)的支架，B型有一個(gè)右側(cè)的支架。除了左右側(cè)之外，該產(chǎn)品在設(shè)計(jì)上沒(méi)有區(qū)分。Beginwiththecustomer’srequirements.以顧客的要求起先Thecustomer’sassemblyplantisrepresentedwithafactoryiconplacedintheupperright-handportionofthemap.Underneath,drawadataboxrecordingtherequirementsofthecustomer.AltonaAssemblyoperatesontwoshiftsandrequiresdailyshipments.Typically12,000Aand6,400Bareneededeverymonth.StateStreetrequestspalletizedreturnabletraywith20bracketsinatrayandupto10traysonapallet.18,400pcs/day-12,000“A”-6,400“B”Box=20pieces2shiftsAltonaAssemblyMachiningWasherAssemblyShippingRawHsg5daysC/T=20secC/O=1hrUptime:65%C/T=10secC/O=0Uptime:95%C/T=55secC/O=10minUptime:100%20,000A15,000B25,000A18,000B15,000A8,000BThenextstepistodrawthebasicproductionprocesses.Toindicateaprocessweuseaprocessbox.Undereachprocessingstep,wewritewithinthedataboxkeyinformation:thecycletime,thechangeovertime,andtheuptime.下一步是繪制基本生產(chǎn)過(guò)程。我們用一個(gè)過(guò)程框來(lái)表示一個(gè)過(guò)程。在每個(gè)過(guò)程，我們?cè)跀?shù)據(jù)框里寫(xiě)下重要信息：周期時(shí)間，換型時(shí)間和牢靠性。Asyouwalkthematerialflowyouwillfindplaceswhereinventoryaccumulates.Thesepointsarewheretheflowisstopping.Weindicatethiswithtombstonestoindicate“dead”flow.ShowProcessesinourplant繪制工廠里的各個(gè)過(guò)程22,000pcs/day-14,000“A”-8,000“B”Tray=20pieces2shiftsAltonaAssembly18,400pcs/day-12,000“A”-6,400“B”Box=20pieces2shiftsIncludethesuppliers包括供應(yīng)商MachiningWasherAssemblyShippingRawHsg5daysC/T=20secC/O=1hrUptime:65%C/T=10secC/O=0Uptime:95%C/T=55secC/O=10minUptime:100%20,000A15,000B25,000A18,000B15,000A8,000B22,000pcs/day-14,000“A”-8,000“B”Tray=20pieces2shiftsAltonaAssemblyPortCastingTues&ThursAttheotherend,werepresentthecastingsupplierwithanotherfactoryicon.Weusethetruckiconandbroadarrowtoshowmovementofmaterialfromthesuppliertoourplant.18,400pcs/day-12,000“A”-6,400“B”Box=20pieces2shiftsButhowdoesthein-plantprocessesknowwhattomake?廠內(nèi)過(guò)程怎樣知道生產(chǎn)什么？Whattomake?做什么？Howmuchtomake?做多少？Howmuchtopurchase?買多少？Weneedtoaddthesecondaspectofourvaluestreammap:theinformationflow.須要加上價(jià)值流的其次部分：信息流。TheInformationFlow信息流TheProductionControlDepartmentisdrawnwithaprocessbox.用一個(gè)過(guò)程框表示生產(chǎn)管理科。ProductionControlcollectsinformationfromitscustomersandsendsspecificinstructionstoeachmanufacturingprocessaboutwhatitshouldproduce.生產(chǎn)管理可從客戶那里收集信息并下達(dá)具體的生產(chǎn)指令給每一個(gè)生產(chǎn)過(guò)程，告知他們應(yīng)生產(chǎn)什么。TheInformationFlow信息流TransferWasherAssemblyShippingRawHsg5daysC/T=20secC/O=1hrUptime:65%C/T=10secC/O=0Uptime:95%C/T=61secC/O=10minUptime:100%20,000A15,000B25,000A18,000B15,000A8,000B22,000pcs/day-14,000“A”-8,000“B”Tray=20pieces2shiftsStateStreetAssemblyMachining加工Washer洗滌Assembly組裝Shipping發(fā)貨RawHsg5daysC/T=20secC/O=1hrUptime:65%C/T=10secC/O=0Uptime:95%C/T=55secC/O=10minUptime:100%20,000A15,000B25,000A18,000B15,000A8,000B22,000pcs/day-14,000“A”-8,000“B”Tray=20pieces2shiftsAltonaAssemblyTues&ThursTues&ThursPortCastingProductionControl生產(chǎn)管理Forecast預(yù)報(bào)Weekly周Forecast預(yù)報(bào)Weekly周WeeklySchedule周進(jìn)度DailyShipSchedule每天發(fā)貨支配1xDaily18,400pcs/day-12,000“A”-6,400“B”Box=20pieces2shiftsAddLeadTimes加上生產(chǎn)周期TransferWasherAssemblyShippingRawHsg5daysC/T=20secC/O=1hrUptime:65%C/T=10secC/O=0Uptime:95%C/T=61secC/O=10minUptime:100%20,000A15,000B25,000A18,000B15,000A8,000B22,000pcs/day-14,000“A”-8,000“B”Tray=20pieces2shiftsStateStreetAssemblyMachiningWash