價值流圖分析

ValueStreamMapping

價值流圖析PartI:CurrentStateMapping第一部分：現狀圖ProductionControlSchedulingCustomer客戶Suppliers供應商Purchasing?Materials?Manpower?PriorityManpowerAvailableDelayMakePartsPaintDeptMaterialAvailableDelayExpediteStorageStorageNeedPartsIntroduction簡介ValueStreamAnalysisisaneffectivetoolininitiatingprocessimprovements.Thetoolprovidesanoverviewofthecurrentmanufacturingoperation,notingconstraintsandareasofconcern.Itprovidesforasystem-wideapproachtoidentifyingareasthatneedattentionanddevelopingplansforthateffort.在改善初期，價值流分析是一個有效的工具。這個工具供應了當前制造過程的總的看法，注釋了瓶頸和涉及到的區(qū)域。它供應了一種系統(tǒng)化的途徑,來區(qū)分須要留意的地方,以及為此努力而制定的支配.VSAProcessMappingBenefits

過程圖的優(yōu)點Obtaincurrentplantoperatinginformation獲得當前車間的業(yè)務資料Obtaincurrentmetricsinformation獲得當前的數據資料Identifiesinventoryandwhereitisstored區(qū)分在庫及其地點Showsmaterialflow表明原料的流淌Givesyouabaselineonwhereyouareandatooltochartyourprogressafterimplementingimprovementswithintheplant在車間內實行改進后，給你一個繪制你進步的基點和工具Objectivesfor

ValueStreamAnalysis

價值流析的目標Understandthebenefitsofprocessmapping理解過程圖的優(yōu)點Developaprocessmapusingicons用圖標來繪制過程圖Understandhowtheprocessmapwillbeusedtodevelopcurrentstatebaselines,stretchobjectivesandimprovementactions理解怎樣用過程圖來發(fā)展當前狀態(tài)基線，展望遠景和改進行為。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.價值流是制造產品所必需的全部活動的集中。這就包括了產生價值和不產生價值的全部活動。TheBIG

Picture整體性Usingthevaluestreamanalysismeansworkingonthebigpicture,notjusttheindividualprocesses;improvingthewhole,notjustoptimizingtheparts.運用價值流分析意味著在整體上工作，不僅僅是個別的生產過程；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.這里我們將把重點放在工廠車間與車間的生產流程上面。它包括接收和貨運TotalValueStream價值流OurFocus重點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.隨著閱歷的增長，你能夠向外擴展到包括從供貨商到消費者的連續(xù)流。Likewise,oureffortswillnotgetintothedetailsofeachdepartments’specificsofoperation.同樣的，我們的重點不會陷入獲得每個部門具體的操作微小環(huán)節(jié)。Thisisnota

computerprocess

這不是一個運用

計算機的過程ValueStreamMappingisapencilandpapertoolthathelpsyoutoseeandunderstandtheflowsofmaterialandinformationasaproductmakesitswaythroughthevaluestream.價值流圖是以筆和紙為工具來幫助你在產品通過價值流時看清和理解物料和信息的流向。Materialand

InformationFlow

材料和信息流Themovementofmaterialisusuallywhatcomestomindwhenwediscuss“productionflow”.當我們談論產品流程時，通常想到的是材料的流淌。Butthereisanotherflow-ofinformation-whichtellseachprocesswhattomakeordonext。但還有一種-信息流，它能告知你每個過程做什么和將要做什么。Youmustmapbothofthem.你必需同時圖析他們ProductionFlowinformationmaterialUsingtheMappingTool

運用圖析工具

First,wedrawthecurrentstatemapbygatheringinformationdirectlyfromtheshopfloor.首先，我們應運用從車間干脆采集的信息來繪制現在狀態(tài)圖。ProductFamily產品系列CurrentStateDrawing現狀圖FutureStateDrawing將來圖WorkPlan支配UsingtheMappingToolFromthis,webegintodrawourideal,orimproved,operation;ourFutureStateMap.從這里我們起先畫志向和改良的操作；我們的將來狀態(tài)圖。ProductFamily產品系列CurrentStateDrawing現狀圖FutureStateDrawing未來狀態(tài)圖WorkPlan工作計劃UsingtheMappingToolThefinalstepistoimplementaplantotransitiontheplantfromthecurrentstatetothefuturestate.最終的步驟是執(zhí)行從現在到將來狀態(tài)工廠轉變的支配ProductFamilyCurrentStateDrawingFutureStateDrawingWorkPlanFocusononeProductFamily重點在一種產品Drawingallyourproductflowsononemapwilltoocomplicated.在一幅圖里畫出全部的產品太困難。ValueStreamMappingmeanswalkinganddrawingtheprocesssteps(materialandinformation)foroneproductfamilyfromdoortodoorintheplant.價值流圖析意味著從工廠的一個車間到另一個車間畫出一種產品的生產步驟。 DrawingaCurrentStateMap繪制一幅現狀圖

Mappingbeginsatthelevelofdoor-to-doorflowinyourplant.在你的工廠里門對門的流淌水平下起先繪圖。Processingcategoriesareidentifiedratherthanrecordingeachandeverystep.過程種類的確定遠勝于每個步驟的記錄?！癈utting”,“Welding”,“Stitching”切割，焊接，縫紉。TheIconsUsed.所用圖標Weusesymbols,oricons,torepresentprocessesandflow.我們用標記，圖標來代替過程和流向。AssemblyABCCorp.MovementofProductionMaterialsMovementoffinishedgoodstotheCustomerInventoryRailShipments_/wkMaterialQueue(sequenced)ConveyanceRoutePullofMaterialfromoneprocesstonext_hour_hour

TankShipment__/wkTheIconsUsed(cont’d)ElectronicInformationFlowProductionSchedule

ManualInformationFlowweeklySignalProductionCardProductionInstructionFlowIndicatespathofProductionInstructionCardIndicatespathofMaterialwithwithdrawcardSequentialProductionScheduleProductionInstructionCardMaterialWithdrawCard

MarketplaceABCBufferorEmergencyStockABCMappingTips

繪圖技巧

Collectdatafromtheactualfloor.從現行的工廠收集資料Walktheentiredoor-to-doorvaluestream.沿著整個門到門的價值流走。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價值流。Resistthetemptationtouseacomputer.抵制住計算機的誘惑DrawingtheCurrentStateMap繪制現狀圖AnExample:一個實例：AcmeManufacturingproduceswidgets.Thewidgetsareproducedintwoversions:style-type“A”andstyle-type“B”.TheAstylehasaleft-handmountingbracketandtheBstylehasright-handmountingbracket.Thereisnovariabilityinthedesignbeyondtheversionsofthemountingbracket.阿克米加工廠生產以中小部件。有兩種型號：A和B型。A型有一個左側的支架，B型有一個右側的支架。除了左右側之外，該產品在設計上沒有區(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過程。我們用一個過程框來表示一個過程。在每個過程，我們在數據框里寫下重要信息：周期時間，換型時間和牢靠性。Asyouwalkthematerialflowyouwillfindplaceswhereinventoryaccumulates.Thesepointsarewheretheflowisstopping.Weindicatethiswithtombstonestoindicate“dead”flow.ShowProcessesinourplant繪制工廠里的各個過程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?廠內過程怎樣知道生產什么？Whattomake?做什么？Howmuchtomake?做多少？Howmuchtopurchase?買多少？Weneedtoaddthesecondaspectofourvaluestreammap:theinformationflow.須要加上價值流的其次部分：信息流。TheInformationFlow信息流TheProductionControlDepartmentisdrawnwithaprocessbox.用一個過程框表示生產管理科。ProductionControlcollectsinformationfromitscustomersandsendsspecificinstructionstoeachmanufacturingprocessaboutwhatitshouldproduce.生產管理可從客戶那里收集信息并下達具體的生產指令給每一個生產過程，告知他們應生產什么。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生產管理Forecast預報Weekly周Forecast預報Weekly周WeeklySchedule周進度DailyShipSchedule每天發(fā)貨支配1xDaily18,400pcs/day-12,000“A”-6,400“B”Box=20pieces2shiftsAddLeadTimes加上生產周期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