企業(yè)職業(yè)培訓(xùn)22價(jià)值流圖析

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?PriorityManpowerAvailableDelayMakePartsPaintDeptMaterialAvailableDelayExpediteStorageStorageNeedPartsProcessMappingBenefits

過程圖的優(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)分在庫及其地點(diǎn)Showsmaterialflow表明原料的流動(dòng)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ObjectivesforValueStreamAnalysis

價(jià)值流析的目標(biāo)Understandthebenefitsofprocessmapping理解過程圖的優(yōu)點(diǎn)Developaprocessmapusingicons用圖標(biāo)來繪制過程圖Understandhowtheprocessmapwillbeusedtodevelopcurrentstatebaselines,stretchobjectivesandimprovementactions理解怎樣用過程圖來發(fā)展當(dāng)前狀態(tài)基線，展望遠(yuǎn)景和改進(jìn)行為。Aging9天周計(jì)劃禮拜四禮拜二/禮拜四2天15天3天(0.5天)3天鋼鐵供應(yīng)商禮拜一/三/五壓合工程熱合工程顧客B顧客A生產(chǎn)控制每月訂單3件產(chǎn)品7天-3班/星期批量生產(chǎn)-1個(gè)星期的量轉(zhuǎn)換時(shí)間-4小時(shí)轉(zhuǎn)換的頻率-7個(gè)班不良率-7%停機(jī)時(shí)間比率-11%“Y”Avg.strokes/hour月需求量-18,000節(jié)拍時(shí)間=60”理想周期=360”不良率-3%重修率-20%停機(jī)時(shí)間比率10%2hrsOT56件/月-人月需求量-18,000生產(chǎn)時(shí)間–450分鐘每班2班20天每個(gè)月節(jié)拍時(shí)間=60”理想周期=240”不良率-7%重修率-12%9件/月-人制造工程焊接工程ExampleofaCurrentStateMap9天9天Definition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)。TheBIGPicture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OurPlantand/orCompany車間或公司Customer顧客OurScope(cont’d)我們的范圍（續(xù)）Asyourexperiencegrows,youcanexpandoutwardtoincludetheflowfromsupplierstocustomers.隨著經(jīng)驗(yàn)的增長，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)陷入獲取每個(gè)部門詳細(xì)的操作細(xì)節(jié)。Thisisnotacomputerprocess

這不是一個(gè)使用計(jì)算機(jī)的過程ValueStreamMappingisapencilandpapertoolthathelpsyoutoseeandunderstandtheflowsofmaterialandinformationasaproductmakesitswaythroughthevaluestream.價(jià)值流圖是以筆和紙為工具來幫助你在產(chǎn)品通過價(jià)值流時(shí)看清和理解物料和信息的流向。MaterialandInformationFlow

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動(dòng)。Butthereisanotherflow-ofinformation-whichtellseachprocesswhattomakeordonext。但還有一種-信息流，它能告訴你每個(gè)過程做什么和將要做什么。Youmustmapbothofthem.你必須同時(shí)圖析他們ProductionFlowinformationmaterialUsingtheMappingTool

運(yùn)用圖析工具First,wedrawthecurrentstatemapbygatheringinformationdirectlyfromtheshopfloor.首先，我們應(yīng)運(yùn)用從車間直接采集的信息來繪制現(xiàn)在狀態(tài)圖。ProductFamily產(chǎn)品系列CurrentStateDrawing現(xiàn)狀圖FutureStateDrawing將來圖WorkPlan計(jì)劃UsingtheMappingToolFromthis,webegintodrawourideal,orimproved,operation;ourFutureStateMap.從這里我們開始畫理想和改良的操作；我們的將來狀態(tài)圖。ProductFamily產(chǎn)品系列CurrentStateDrawing現(xiàn)狀圖FutureStateDrawing未來狀態(tài)圖WorkPlan工作計(jì)劃UsingtheMappingToolThefinalstepistoimplementaplantotransitiontheplantfromthecurrentstatetothefuturestate.最后的步驟是執(zhí)行從現(xiàn)在到將來狀態(tài)工廠轉(zhuǎn)變的計(jì)劃ProductFamilyCurrentStateDrawingFutureStateDrawingWorkPlanFocusononeProductFamily

重點(diǎn)在一種產(chǎn)品Drawingallyourproductflowsononemapwilltoocomplicated.在一幅圖里畫出所有的產(chǎn)品太復(fù)雜。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.在你的工廠里門對門的流動(dòng)水平下開始繪圖。Processingcategoriesareidentifiedratherthanrecordingeachandeverystep.過程種類的確定遠(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)來代替過程和流。制造合作公司_hour_hour__/wk數(shù)據(jù)框在庫及數(shù)量成品向顧客的流動(dòng)原材料在廠內(nèi)的流動(dòng)順序生產(chǎn)流公路運(yùn)輸(每周幾次)運(yùn)輸途徑(多長時(shí)間)原材料被下個(gè)工序拉動(dòng)指導(dǎo)生產(chǎn)信息流ABC(產(chǎn)品)市場Aging必須在庫時(shí)間手工信息流電子信息流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：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)上沒有區(qū)別。Beginwiththecustomer’srequirements.以顧客的要求開始Thecustomer’sassemblyplantisrepresentedwithafactoryiconplacedintheupperright-handportionofthemap.Underneath,drawadataboxrecordingtherequirementsofthecustomer.客戶的公司以右上角的符號標(biāo)志，下面畫一個(gè)數(shù)據(jù)框來記錄客戶的要求。AltonaAssembly公司兩班生產(chǎn)，每天都需要運(yùn)輸產(chǎn)品。一般每月需求12,000A和6,400B.StateStreetrequestspalletizedreturnabletraywith20bracketsinatrayandupto10traysonapallet.18,400件/天-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)過程。我們用一個(gè)過程框來表示一個(gè)過程。在每個(gè)過程，我們在數(shù)據(jù)框里寫下重要信息：周期時(shí)間，換型時(shí)間和可靠性。Asyouwalkthematerialflowyouwillfindplaceswhereinventoryaccumulates.Thesepointsarewheretheflowisstopping.Weindicatethiswithtombstonestoindicate“dead”flow.ShowProcessesinourplant繪制工廠里的各個(gè)過程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=20pieces2shiftsTheInformationFlow信流TheProductionControlDepartmentisdrawnwithaprocessbox.用一個(gè)過程框表示生產(chǎn)管理科。ProductionControlcollectsinformationfromitscustomersandsendsspecificinstructionstoeachmanufacturingprocessaboutwhatitshouldproduce.生產(chǎn)管理可從客戶那里收集信息并下達(dá)詳細(xì)的生產(chǎn)指令給每一個(gè)生產(chǎn)過程，告訴他們應(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)貨計(jì)劃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%20,000A15,000B25,000A18,000