精益生产之价值流图Value_Stream_Mapping

Value Stream Mapping
2
Learning Objectives

Define
The learning objectives for this course are:

Be able to create Current State and Future State Value Stream Maps Be able to use customer and business requirements to prioritize improvement opportunities

Step 4: Step 5: Step 6: Step 7:

Draw Process Flow Draw Material Flow Draw Information Flow Process Data Collection


Step 8: Add Process and Lead Time data Step 9: Verify Current State Map
300 Per Day 400 Min Avail 1 Shift C/T 12 Min
Single Plant
1200 Min Avail
3 Shift C/T 3 Min
Process Steps
Value Stream Mapping
11
Router Steps
Define
Measure
Analyze
Mat Bin
Forge Machine
Module
Assembly
TPM
Batch
200 pcs
Set-up Reduction
FIFO
Max 100 pcs
Assembly
2/Day
FIFO
Max 200 pcs
DIST
C/T = 30 Sec C/O = 30 Min Uptime 95% Batch Size 100

Identify and Prioritize Improvement Opportunities Determine Future State Implement Improvements to Achieve Future State
6
Value Stream Mapping
Value Stream Manager
Define
Measure
Value Stream Mapping
Analyze
Improve
Control
Agenda

Define
Monday
Kick-Off Introductions Current State Steps 1-4


Tuesday

Current State Steps 5-7
A high-level SIPOC chart helps to identify the process output(s) and the customers of that output so that the Voice of the Customer can be captured
Value Stream Mapping
5000 pcs
C/T = 60 Sec C/O = 5 Min Uptime 95% Batch Size 100
100 pcs
C/T = 50 Sec
C/O = 10 Min Uptime 95% Batch Size 100
200 pcs
15 hours 30 sec 45 sec
83 hours 60 sec
S U P P L I E R
Value Stream Mapping
Measure
Value Stream Mapping
SIPOC Top-Down
Analyze
Map Mapping
Value-Stream
Improve
Control
Process Mapping Hierarchy
SIPOC chart
S U P P L I E R I N P U T


Value Stream Mapping
7
Current State VSM
6 Month Forecast
SUPPLIER
Define
ASSEMBLY
90/60/30 Day
Customer
MRP
1/Week
Production Control
Daily Order
Weekly Fax
20,000 pcs/mo Module=100
•O-ring, bearing, snap ring • Daily schedule
Assembly DIST
C/T = 30 Sec C/O = 30 Min Uptime 75% Batch Size 100
1000 pcs
C/T = 45 Sec C/O = 60 Min Uptime 95% Batch Size 100
Define
PROCESS
O U T P U T
C U S T O M E R
Company
Top Down Process Flow
Step 1
4
Mult. Plants
VSM
48
I
Step 2 2
180 Per Day
22
I
Step 3 1
450 Per Day 400 Min Avail 1 Shift C/T 7 Min
13
Step 1: The SIPOC Chart
Translate
Define
Customer requirements into output specifications and identify related Key Process Output Variables (KPOVs) Go Upsteam to the Process Steps(s) which most impact the OUTPUT and determine the Key Process Input Variables (KPIVs) Try to use Leading Measure(s) (instead of Lagging Measures – if lagging, then Close/Reduce amount of Lagging)
Supplier Input Process Output Customer (SIPOC) Map
Step 1
Improve
Control
Step 1: High-Level SIPOC Chart

Define
Supplier Input Process Output Chart (SIPOC)
2 hours 50 sec
4 hours
Production lead time = 104 hours 3 min Processing time = 185 seconds
8
Value Stream Mapping
8
Future State VSM
6 Month Forecast
SUPPLIER

Wednesday


Current State Steps 8-9 Identify and Prioritize Improvement Opportunities Create Future State

Thursday
Prepare for Presentation Presentation

The learning objective for this course is not:

To teach Lean Tools to help achieve Future State
Value Stream Mapping
3
What’s in It for Me?

Define
Value stream mapping is a visual tool to help understand the current value stream.

Define
Assign Value Stream Manager

One person to manage the mapping of the total flow Has the capability to make changes across departmental boundaries Leads the creation and prioritization of the implementation plan for getting from present state to future state Monitors implementation and updates implementation plan Driver for results
C/T = 45 Sec
C/O = 10 Min Uptime 95% Batch Size 100
500 pcs
C/T = 60 Sec C/O = 5 Min Uptime 95%
Module Size100
C/T = 50 Sec C/O = 10 Min Uptime 95%
Module Size 100
Value Stream Mapping
4
Teaching Approach

Define
Teach appropriate Value Stream Mapping step
Show simplified example Show complex real world example Work B&D Industries Exercise in teams Apply learning to Flygt process
Define
ASSEMBLY
90/60/30 Day
Customer
Production Control
Daily Order Daily Order
20,000 pcs/mo Module=100
Da百度文库ly
Mat
1) Set-up reduction 2) Pull Systems 3) TPM
Receiving Warehouse

Customers: Companies X, Y, & Z Outputs:
Cost, Quality, On-Time Delivery


Process:
Inputs: Suppliers:
Produce Products 1, 2, 3, 4 & 5
Raw Material Companies A, B & C
It allows people to easily understand where waste exists in the process. It gives the team a basis for prioritizing improvement efforts.



It gives the team a visual tool for representing their improvement ideas, so they are better able to communicate with people inside and outside the organization.
2.5 hours 30 sec
10 hours
2 hours 60 sec
4 hours
Production lead time = 18 hours 33 min Processing time = 185 seconds
45 sec
50 sec
9
Value Stream Mapping
9
Define
Value Stream Mapping
5
Value Stream Mapping Process Steps

Define
Identify Current State
Step 1: SIPOC Chart Step 2: Top Down Flow Chart Step 3: Determine Product Family
Daily Release
Receiving Warehouse 2/Day
•Raw material •Daily schedule
Forge
•Forge material •Daily schedule
Machine
• Bolts, nuts, washers • Daily schedule
Assembly