1、105 价值流分析精益管理系列课程HeijunkaAveraged daily volume & mixSmooth production scheduleStandard WorkKaizenJidokaBuilt-in qualityPokayoke5 WhyHarmony of man & machineCreative Idea Suggestion System5S3PTPMSMEDVisual ControlsKanbanOperational ExcellenceBest Cost, Quality, DeliveryEmpowered employeesCustomer foc
2、used cultureTPSJust In TimeTakt TimeOne-piece FlowDownstream Pull价值流分析内容安排 什么是价值流? 什么是价值流图 (VSM)? 为什么采用价值流分析? 价值流分析逐步展开什么是价值流 完成顾客要求所需的步骤或活动 其中包括增值和不增值 显示作业流动 (物料和信息) 实例: “定单到现金 ” “概念到发布 ” “定单到发运 ”价值流图的来源MIF = 物料和信息流程图由丰田公司开发用于分析和改进流程的工具价值流分析可用于任何生产或服务活动。要求交付需求供应集团级公司级= 流程部门级绘制层次目视 整体流程目视化，而不仅仅是单个流程
3、 从顾客角度看待流程（外部顾客） 上游对下游工序的影响 (内部顾客) 便于识别流程中浪费 显示物料和信息流之间的联系 将不同部门或职能的问题联系在一起为什么采用价值流图改变 提供改进活动实施的蓝图 易于实际作业员工参与 激发员工从不同角度看问题 提供流程观察的共同语言 将所有信息显示在一起为什么采用价值流图聚焦 关注流程 (而非产品) 关注系统 (而非局部优化) 改进活动与业务目标相联系 改进正确的区域为什么采用价值流图价值流分析活动的输出 现状图 : 显示现时物流和信息流 识别浪费和系统问题 未来图: 显示目标物流和信息流 减少浪费，实施精益系统 实施工作计划达到未来状态 设定变革计划优先权
4、Assembly45,000pcs/mo- 5,400 P- 3,940 NPTray = 20 pcs2 shifts1xDailyOCT2 shiftsC/O%UPProductivityVA Space/ratioBefore AfterProduct travel120 seconds0 min90%5 boxes/person/hr0ft2/(1/50)150ft600 P pcs155 NP pcs5,400P pcs3,940 pcsInformation flow Product flowManual Push+SHIPPING 527,600 sec/shift+ +I270
5、0P1440NPI950P500NPI355OCT2 shiftsC/O%UPFPY or RTYVA TimeProductivityVA Space/ratioBefore AfterProduct travel200 seconds0 min90%95% or 72.9%12.5 pcs/person/hr6ft2/(1/20)25 sec256ft355 pcs 400P pcs500NP pcsInformation flow Product flowManual Push+ASSEMBLY #2 127,600 sec/shiftOCT2 shiftsC/O%UPFPY or RT
6、YVA TimeCell ProductivityVA Space/ratioBefore AfterProduct travel40 seconds0 min90%95% or 72.9%10 pcs/person/hr2ft2/(1/100)35 sec30ft125pcs 0 pcsInformation flow Product flowManual PushGRIND 127,600 sec/shiftAuto 55 seconds375IOCTAutoC/O%UPFPY or RTYVA TimeProductivityVA Space/ratioBefore AfterProdu
7、ct travel30 seconds30 min90%85% or 59%150 pumps/person/hr2ft2/(1/300)5 sec660ft550pcs 2,100P pcs1,285NP pcsInformation flow Product flowManual PushPAINT 260 sec/shiftEPE 3 daysOCT3 shiftsC/O%UPFPY or RTYVA TimeCell ProductivityVA Space/ratioBefore AfterProduct travel160 seconds60 min90%98% or 74%10
8、pcs/person/hr0.5ft2/(1/500)15,000 sec1200ft190pcs 250pcsInformation flow Product flowManual PushHEAT TREAT TRE 340,000 sec/shiftAuto 54,000 secondsI340OCT3 shiftsC/O%UPFPY or RTYVA TimeVA SpaceBefore AfterProduct travel55 seconds90 min90%95% or 72.9%2ft235 sec25ft125pcs 150pcsInformation flow Produc
9、t flowManual PushTURN #2 140,000 sec/shiftAuto 45 secondsVA Space/ratio 2/(1/100)275IOCT3 shiftsC/O%UPFPY or RTYVA TimeVA SpaceBefore AfterProduct travel45 seconds90 min90%95% or 72.9%2.25ft245 sec25ft225pcs 150pcsInformation flow Product flowManual PushMILL 140,000 sec/shiftAuto 55 secondsVA Space/
10、ratio 2.25/(1/200)IOCT2 shiftsC/O%UPFPY or RTYVA TimeVA SpaceBefore AfterProduct travel45 seconds0 min90%95% or 72.9%2.5ft245 sec500ft125pcs 150pcsInformation flow Product flowManual PushTURN #1 127,600 sec/shiftAuto 55 secondsVA Space/ratio 2.5/(1/100)3750.4D21D0.2D 0.3D 0.4D 0.3D 1.5D 4.1D100S 100
11、S 100S54.1KSec95Sec200Sec90Sec120Sec45S45S35S15KSec35Sec25Sec5Sec50025travelVA Space(ratio)25 1200 30 256 660 150 4502.5(1/100)2.25(1/200)2.0(1/100)2.5(1/500)2.0(1/100)2.0(1/20)2.0(1/300)0.0(1/50)Tues. +ThursGembaForging Co.2000 pcs326615.2516.9KSec28.8DaysPRODUCTIONCONTROLMRPDailyOrder30/60/90 dayF
12、orecastsWeeklyRelease6-weekForecastsFORGING RMFO现状图 现状图代表观察现有价值流的实际状态。 从顾客开始 (需求) 定义数据表 (流程) 画出材料流 (推动，拉动) 画出信息流 (触发)现状图绘制的十大步骤1. 选择价值流 识别主要价值流 分析产品族 分析顾客需求2. 绘制整体作业流动3. 识别关键指标4. 完成数据表5. 绘制等待天数6. 填充时间线7. 计算增值比例8. 绘制原材料供应9. 绘制信息流10. 识别改善项目OCT2 shiftsC/O%UPFPY or RTYVA TimeProductivityVA Space/ratioBe
13、fore AfterProduct travel110 seconds0 min95%98% or 76%40 pcs/person/hr4ft2/(1/20)25 sec25ft5pcs5pcsInformation flow Product flowManual Pull+ASSEMBLE & PAINT & PackAS & P & P ck227,600 sec/shiftOCT2 shiftsC/O%UPFPY or RTYVA TimeProductivityVA Space/ratioBefore AfterProduct travel90 seconds20 min98%98%
14、 or 78%25 pcs/person/hr2ft2/(1/20)135sec20ft4pcs 5pcsInformation flow Product flowMPulRotor Cell227,600 sec/shiftAuto 220 secondsOCT2 shiftsC/O%UPFPY or RTYVA TimeProductivityVA Space/ratioBefore AfterProduct travel120 seconds20 min95%98% or 78%25 pcs/person/hr8ft2/(1/20)185sec20ft15pcs 5pcsInformat
15、ion flow Product flowMPulHousing Cell127,600 sec/shiftAuto 200 secondsOCT2 shiftsC/O%UPFPY or RTYVA TimeProductivityVA Space/ratioBefore AfterProduct travel89 seconds20 min95%98% or 78%25 pcs/person/hr8ft2/(1/20)185sec20ft5pcs 5pcsInformation flow Product flowMPulManifold CellMan fold Cell227,600 se
16、c/shiftAuto 200 secondsOCT2 shiftsC/O%UPFPY or RTYVA TimeProductivityVA Space/ratioBefore AfterProduct travel90 seconds20 min98%98% or 78%25 pcs/person/hr2ft2/(1/20)135sec20ft4pcs 5pcsInformation flow Product flowMPulRotor Cell227,600 sec/shiftAuto 220 secondsFORGING RMAssembly45,000pcs/mo- 5,400 P-
17、3,940 NPTray = 20 pcs2 shifts1xDailydailyGembaForging Co.2000 pcsPRODUCTIONCONTROLMRPDailyOrder30/60/90 dayForecastsWeeklyRelease6-weekForecasts未来状态图未来状态图代表在未来的6个月将要达到的理想状态。设定改进目标20,000 PPM$187,000 / 人2,225 m23 天$230,000$130,000$340,000未来56%45,000 PPM缺陷34%$139,000 / 人生产率55%5,000 m2场地83%17 天交货期58%$54
18、5,000成品72%$450,000在制品32%$500,000原材料%现状指标价值流实施计划 简单最佳! 使用一页计划文件来识别做什么，谁来做，时间和结果。价值流计划可以使用以下几种格式: X-矩阵 甘特图 保龄球图 A3 报告1st Level Policy DeploymentX Reduce signal to material receipt X 12 X Reduce material receipt to assembly complete lead time X21XX Direct material cost X1XX Acq rate effectivenessReduce
19、timetomarketby2 monthsReducecostby7%Supplierlead-timesto10.5monthsorless(1.5month reducReduce to13daysorless(0.5month reduction)1%reduction6%reductionGregBToddJimPJimHHerb Deb MikeE6/1/2004 (OIF) Resources - “Who“31-Dec-04 G = On Time 1 Primary Responsibility31-Dec-04 Y = Slipping 2 Secondary Respon
20、sibility31-Dec-04 R = LateStrategies to Achieve Objectives - “How“Annual Breakthrough Objectives - “What“Deliverables &Measures - “How much“Timeline - “When“Company供应商卡车运输推动箭头给顾客的成品F I F OMax. 20 pcs First In First Out按序流动超级市场拉动缓存或安全库存C/T = 20 sec.C/O= 1000 sec.2 Shifts数据框Attach Bracket库存物料流动符号人工信息流电子信息流Weekly ScheduleO X O X平顺化(均匀品种和产量)取货看板 生产看板 信号看板看板箱批量到达看板 序列拉动球“ 现场查看” 排程信息流动符号
