02 精益价值链图
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Inside Sales Jackson ( 9 ) E nter order into MRM S Submit quote/ confirmation
Phone, Fax, Email, EDI Daily
CUSTOM ER
Loc: War $: OTD %: Returns: Orders/ Wk: Del.Freq:
十二个月的推进计划与评量 1212 -Month GoGo -Forward Plan with Metrics
天 行 健 企 业 管 理
TXJ management science
3-3
什么是企业的图? 天行健企业管理
What is an Enterprise Map?
了解目前的状态 Understanding the current condition:
天行健企业管理
价值链图 Value Chain Mapping
目前状态 The Current State
天行健企业管理 何谓价值链图 ?
What Is Value Chain Mapping?
它是一种工具, 其用途是 A tool used to:
根据问题和机会及其对系统的影响, 找出有关项目, 并予以排序 Identify and prioritize projects based on problems & opportunities and their effects on the system 计算 Calculate: 总的运作时间 Total lead time 增值时间 Value-added time 增值比例 Value-added ratio 显示从客户到供应基地的物流和信息流 Display material and information flow from the customer through the supply base 排定优先次序, 找出改善机会 Establish project priority and identify opportunities 确定改善目标, 制定量度方法 Identify and set goals for improvement metrics
? tons daily ? trucks
Shipping Load Trucks
1500 tons daily 60 trucks
Response Time A ve rage produc t lead time from me lt to ship Total Plant Inventor y
人员 Man 物料 Material 方法 Method 机器 Machine
供应商
Supplier 员工 People 政策 Policy 产品 Product 程序 Procedure
客户
Customer
产品流与信息流的知识 Knowledge of product & communication flow 实际而定量化的现场资料 Quantitative factual “live data” information 了解客户、生产系统、流程、运作及供应基地 Understanding of the customer, manufacturing system, processes, operations & the supply base 天 行 健 企 业 管 理
= 1%
On Time D elivery: FY 02 Inventory Turns:
S chedule I RAW 30000 20 d M elt S chedule Created
I Finish Goods 24 d
S chedule Melting # Operators: 5 per shft # S hifts: 3 V/A C/T : 88 min Process Time : 115 min Rework: .05% S crap: 0 C/O Time: N/A Downtime: Batch Size: 57.3 tons FP Y: ? Refining # Operators: 2 per shft # S hifts: 3 V/A C/T : 44 min Process Time : 115 min Rework: .05% S crap: 0 C/O Time: N/A Downtime: Batch Size: 57.3 tons FP Y: ? Hot Roll S chedule created
TXJ management science
3-4
天行健企业管理
价值链图标记 Value Chain Map Symbols
= 前推式箭号 Push arrow = 原料／成品 Raw material / finished goods = 人手操控讯息 (文件化排程) Manual information (paper schedule) = 电子讯息 (EDI, 传真) Electronic information (EDI, fax) = 讯息频率 Information frequency
天 行 健 企 业 管 理
TXJ management science
每周 Weekly
3-5
天行健企业管理
什么是价值链图的焦点? What Is a Value Chain Map’s Focus?
焦点 (Focus):
生产的两个基本成分 Two basic components of manufacturing -1. 物料滞留 Material Stagnation • 原料 Raw Material • 在制品 WIP • 成品 Finished Goods
产品系列应该在销售额或盈利能力方面 对整个公司的业务有重要影响。 The product family should have a significant impact (% of sales or profitability) on the total business. 天 行 健 企 业 管 理
天 行 健 企 业 管 理
TXJ management science
3-2
天行健企业管理
怎样运用价值链图? How Do You Use Value Chain Mapping?
目前状态 Current Condition
与企业目标一致 Align Business Objectives
理想状态 Ideal Condition
TXJ management science
3-8
目前状况－生产 天行健企业管理
Current State-Manufacturing
Metallurgy Review
Macsteel Ft. Smith 的现状价值链 链图
MACSTEEL Ft. SMITH CURRENT STATE VALUE CHAIN MAP
86.5% = 0.10% Throughput: 437,500 tons FY 02 D aily throughput 1500 tons
Schedule S chedule Vendor Schedule OSP Shipping Schedule
Product Mapped: Melt through cast Mac+ 2.5" bar A fte r cast unit of measure is a 2000lb bar:
成品 Finished Goods 客户 Customer
生产商 Manufacturer
预测 Forecast
2.
卖方 Vendor 发放 Release
天 行 健 企 业 管 理
TXJ management science
讯息滞留 Information Stagnation • 预测(未确定) Forecast (not firm) • 发放(未确定) Release (firm) • 生产指示 Production Instruction
SUPPLIER OM NISOURCE
Loc: Jackson MI
QA Test ( 10 ) Define work order Create routing if new
I 1d
P roduction Control
Production Control ( 6)
h Run Daily Batc
3-6
天行健企业管理
有什么东西需要观察 : 从顾客角度看的宏观图 What must be seen: Big picture through Customer’s eyes
顾客从那里发出订单? Where are customer orders sent? 物料是何时订单? When is material ordered? 工人的操作时间 Vs 节拍时间是怎样的? What is Cycle time vs. takt time? 工人是如何知道怎样组装的? How does operator know how to produce?
3-7
天行健企业管理
如何绘制价值链图 ? How Do You Create a Value Chain Map?
第一步 – 选择产品系列 # 1 Step -------Select Select a product family
找出所有物料编号、需求数量、需求时间 Identify all part numbers, quantity required, and when needed 按生产流程分系列 Break into family by process 留意客户的观点 Keep customer’s point of view in mind
4.9 w eeks
30,000 tons raw material, 16,000 tons WIP, 36,000 tons Finished goods 89% Raw/W ip/Fin Avg 6.7 turns
Value Add% = 285 min 30.6 days x 24 hrs x 60 min = 44,064 min
Quality
100% 50% 0%
Roll Mill Testing Bar Turn
.9 67 .90
0.71 2
Create Schedule Set up releases I 1d
Quote/Confirmation back to custom er
A ctual Yield FY 02 Custome r Retur ns F Y02
= 外部资源 Outside source
Weld die
140 / day SOCT 3.88’ C/O 30’ Batch 100
= 生产流程数据方块 Manufacturing process data box
250
I
= 库存 Inventory = 陆路运输 Truck shipment
前置时间 (Lead-time time line): 4 天 (days) = 制程间的时间 Interprocess time (库存 inventory) 2 分钟 (min) = 制程时间 Process time (并非工人的作业时间 not S Operator Cycle Time) 16 秒 (sec) = 制程的增值时间 Process value-added time
什么是价值链图的焦点? What Is a Value Chain Map’s Focus?
供应商 Vendor 1 个月 (Month)
库存 Inventory
Finished
I
PC 每天 (Daily)
成品
Goods
Inspect
品检
客户
Customer
必须能看到宏观情况 (系统)
Must be able to see big picture (system) 同时必须能观察到详情(流程) 天 行 健 企 业 管 理 Must be able to see details (process) at the same TXJ management science time
Inside Sales Jackson ( 9 ) E nter order into MRM S Submit quote/ confirmation
Phone, Fax, Email, EDI Daily
CUSTOM ER
Loc: War $: OTD %: Returns: Orders/ Wk: Del.Freq:
十二个月的推进计划与评量 1212 -Month GoGo -Forward Plan with Metrics
天 行 健 企 业 管 理
TXJ management science
3-3
什么是企业的图? 天行健企业管理
What is an Enterprise Map?
了解目前的状态 Understanding the current condition:
天行健企业管理
价值链图 Value Chain Mapping
目前状态 The Current State
天行健企业管理 何谓价值链图 ?
What Is Value Chain Mapping?
它是一种工具, 其用途是 A tool used to:
根据问题和机会及其对系统的影响, 找出有关项目, 并予以排序 Identify and prioritize projects based on problems & opportunities and their effects on the system 计算 Calculate: 总的运作时间 Total lead time 增值时间 Value-added time 增值比例 Value-added ratio 显示从客户到供应基地的物流和信息流 Display material and information flow from the customer through the supply base 排定优先次序, 找出改善机会 Establish project priority and identify opportunities 确定改善目标, 制定量度方法 Identify and set goals for improvement metrics
? tons daily ? trucks
Shipping Load Trucks
1500 tons daily 60 trucks
Response Time A ve rage produc t lead time from me lt to ship Total Plant Inventor y
人员 Man 物料 Material 方法 Method 机器 Machine
供应商
Supplier 员工 People 政策 Policy 产品 Product 程序 Procedure
客户
Customer
产品流与信息流的知识 Knowledge of product & communication flow 实际而定量化的现场资料 Quantitative factual “live data” information 了解客户、生产系统、流程、运作及供应基地 Understanding of the customer, manufacturing system, processes, operations & the supply base 天 行 健 企 业 管 理
= 1%
On Time D elivery: FY 02 Inventory Turns:
S chedule I RAW 30000 20 d M elt S chedule Created
I Finish Goods 24 d
S chedule Melting # Operators: 5 per shft # S hifts: 3 V/A C/T : 88 min Process Time : 115 min Rework: .05% S crap: 0 C/O Time: N/A Downtime: Batch Size: 57.3 tons FP Y: ? Refining # Operators: 2 per shft # S hifts: 3 V/A C/T : 44 min Process Time : 115 min Rework: .05% S crap: 0 C/O Time: N/A Downtime: Batch Size: 57.3 tons FP Y: ? Hot Roll S chedule created
TXJ management science
3-4
天行健企业管理
价值链图标记 Value Chain Map Symbols
= 前推式箭号 Push arrow = 原料／成品 Raw material / finished goods = 人手操控讯息 (文件化排程) Manual information (paper schedule) = 电子讯息 (EDI, 传真) Electronic information (EDI, fax) = 讯息频率 Information frequency
天 行 健 企 业 管 理
TXJ management science
每周 Weekly
3-5
天行健企业管理
什么是价值链图的焦点? What Is a Value Chain Map’s Focus?
焦点 (Focus):
生产的两个基本成分 Two basic components of manufacturing -1. 物料滞留 Material Stagnation • 原料 Raw Material • 在制品 WIP • 成品 Finished Goods
产品系列应该在销售额或盈利能力方面 对整个公司的业务有重要影响。 The product family should have a significant impact (% of sales or profitability) on the total business. 天 行 健 企 业 管 理
天 行 健 企 业 管 理
TXJ management science
3-2
天行健企业管理
怎样运用价值链图? How Do You Use Value Chain Mapping?
目前状态 Current Condition
与企业目标一致 Align Business Objectives
理想状态 Ideal Condition
TXJ management science
3-8
目前状况－生产 天行健企业管理
Current State-Manufacturing
Metallurgy Review
Macsteel Ft. Smith 的现状价值链 链图
MACSTEEL Ft. SMITH CURRENT STATE VALUE CHAIN MAP
86.5% = 0.10% Throughput: 437,500 tons FY 02 D aily throughput 1500 tons
Schedule S chedule Vendor Schedule OSP Shipping Schedule
Product Mapped: Melt through cast Mac+ 2.5" bar A fte r cast unit of measure is a 2000lb bar:
成品 Finished Goods 客户 Customer
生产商 Manufacturer
预测 Forecast
2.
卖方 Vendor 发放 Release
天 行 健 企 业 管 理
TXJ management science
讯息滞留 Information Stagnation • 预测(未确定) Forecast (not firm) • 发放(未确定) Release (firm) • 生产指示 Production Instruction
SUPPLIER OM NISOURCE
Loc: Jackson MI
QA Test ( 10 ) Define work order Create routing if new
I 1d
P roduction Control
Production Control ( 6)
h Run Daily Batc
3-6
天行健企业管理
有什么东西需要观察 : 从顾客角度看的宏观图 What must be seen: Big picture through Customer’s eyes
顾客从那里发出订单? Where are customer orders sent? 物料是何时订单? When is material ordered? 工人的操作时间 Vs 节拍时间是怎样的? What is Cycle time vs. takt time? 工人是如何知道怎样组装的? How does operator know how to produce?
3-7
天行健企业管理
如何绘制价值链图 ? How Do You Create a Value Chain Map?
第一步 – 选择产品系列 # 1 Step -------Select Select a product family
找出所有物料编号、需求数量、需求时间 Identify all part numbers, quantity required, and when needed 按生产流程分系列 Break into family by process 留意客户的观点 Keep customer’s point of view in mind
4.9 w eeks
30,000 tons raw material, 16,000 tons WIP, 36,000 tons Finished goods 89% Raw/W ip/Fin Avg 6.7 turns
Value Add% = 285 min 30.6 days x 24 hrs x 60 min = 44,064 min
Quality
100% 50% 0%
Roll Mill Testing Bar Turn
.9 67 .90
0.71 2
Create Schedule Set up releases I 1d
Quote/Confirmation back to custom er
A ctual Yield FY 02 Custome r Retur ns F Y02
= 外部资源 Outside source
Weld die
140 / day SOCT 3.88’ C/O 30’ Batch 100
= 生产流程数据方块 Manufacturing process data box
250
I
= 库存 Inventory = 陆路运输 Truck shipment
前置时间 (Lead-time time line): 4 天 (days) = 制程间的时间 Interprocess time (库存 inventory) 2 分钟 (min) = 制程时间 Process time (并非工人的作业时间 not S Operator Cycle Time) 16 秒 (sec) = 制程的增值时间 Process value-added time
什么是价值链图的焦点? What Is a Value Chain Map’s Focus?
供应商 Vendor 1 个月 (Month)
库存 Inventory
Finished
I
PC 每天 (Daily)
成品
Goods
Inspect
品检
客户
Customer
必须能看到宏观情况 (系统)
Must be able to see big picture (system) 同时必须能观察到详情(流程) 天 行 健 企 业 管 理 Must be able to see details (process) at the same TXJ management science time