6西格玛-流程设计

1、 制作跨职能流程图Cross Functional Process Mapping(为流程再造制作流程图)(Process Mapping for Re-design)六西格玛过程设计Six Sigma Process Design制作再设设计流程程图的目目的Re-DesignProcessMapping Objectives了解流程程的基本本情况和和价值链链各环节节的相关关方Givena projectcharterandunderstandingofprocess basicsandthe value chain stakeholders介绍制作跨职职能流程程图,也称为“泳道图“Intro

2、duceCrossfunctional/Deployment Mapping, alsoknownasa“SwimLane”制作基准准图(跨职能流流程图或或泳道图图)CreateBaselineMap (Cross-functional/SwimLaneProcess Map)项目跟踪踪表过程再设设计路线线图Process Redesign Roadmap价值链翻译试的过程程过渡计划划实施收集客户户之声/商业之声声分析要求求再设计过过程解决办法法的设计/开发利益相关关方选择表利益相关关方面谈谈Kano制作精益益流程图图Pugh概念产生生Pugh概念选择择讨论指南南从图片和和声音提提炼要求求要求

3、KJ图片KJ抽样调查查区分优先先次序QFDC&E跨职能流流程图经历利益相关关方的世界总结要求求并区分优优先次序序产生和选选择概念念试解决办办法跨职能流流程图Cross-Functional ProcessMap价值链ValueChain流程图步步骤Process MapProcess StepsManufacturerDealer-Sales-Finance-CustomerServiceBuyer价值链环环节相关关方StakeholdersProcess Step1OfferFinancingOptionsProcess Step2Process Step3Process Step4制作跨职

4、职能流程程图CrossFunctional or DeploymentMapping记载Documents:各个职能能,部门和参参与流程程环节活活动的人人之间的的关系Inter-relationships among functions,departments, peoplewhoare involved in sequentialprocessdeployment activities. (whodoesit)Also known as Swim lane揭示Reveals:障碍,返工渠道道,延迟,未用空间间,需要和产产生的信信息以及及弯路Barriers,rework paths,dela

5、ys, blank spaces,informationneeded andcreated,anddetours步骤Steps:选择范围围ChoseScope明确过程程步骤IdentifyProcess Steps确定顺序序DetermineSequence确定关系系DetermineRelationships画图Draw theMap添加有关关时间,费用,质量,详细输入入和输出出的数据据Adddataontime,cost,quality,detailedinputs&outputs准备确认团队队IdentifytheTeam流程图的的输入InputstoMapping头脑风暴暴Brains

6、torming操作手册册Operatormanuals规范Specifications操作员经经验Operatorexperience六要素6Ms人,机器,方法,测量,材料,环境Man, Machine(Equipment), Method(Procedures), Measurement,Materials, MotherNature(Environment)利益相关关方的输输入Inputfrom Stakeholders制作跨职职能流程程图的步步骤CrossFunctional MappingSteps开始于过程的的流程图图Startwith FlowChartofprocess识别过程所

7、涉涉及的功功能部门门(价值链)并记录在在纸的左左侧IdentifyFunctional groups(ValueChain) thatprocesscrosses andrecordonleftside of page画泳道线把把不同的的职能部部门分开开Draw lines to representthelanesbetweenfunctional groups从图的左侧侧开始,把流程图图的第一一步放在在合适的的泳道里里Startonleft sideofmap,placefirststep fromflowchartinappropriatelane继续把流程的的步骤按按以下的的规则放放在泳

8、道道里Continuetoplaceprocess steps accordingtofollowingguidelines时间从左到右右上升Time increasesfrom lefttorightacross map同时发生的步步骤应上上下叠在在一起Stepsthat occur simultaneously shouldbestacked on topofeach other箭头总是左进进右出Arrowsalways exitonrightand enter on leftsidesofprocesssymbols互相连接的但但至少相相隔一个个泳道的的步骤应应用虚线线连接Process

9、esthatareconnected,butare morethanonelaneapartshouldbeconnected withdotted lines增加流程程描述细细节Increasing ProcessDescriptionDetail流程图(也称方块块图)Flow Chart (akaBlockDiagram)显示过程程步骤,而不是细细节Showsprocess steps,without worrying about details是了解过过程步骤骤的有用用一步Usefulasafirstpass to understandprocesssteps跨职能图图(也称”泳道图”)

10、CrossFunctional Map(aka “Swim lane”)把流程图图过程步步骤重安安排到职职能泳道道里Rearranges flowchartprocessstepsinto lanes of functions清楚地显显示连接接关系Clearly shows hand-offs过程步骤骤从左到到右按时时间前进进Process steps movelefttorightastime progresses跨资源图图CrossResourceMap在职能中中更进一一步,显示实际际资源和和资源之之间的连连接关系系Further drill downintofunctions, show

11、ingactual resource to resource handoffscustomerNoYesNoYesFunction 1Function 2Function 3Function 4Function 1Function 2Function 3Function 4Resource 1Resource 2制作流程程图Process FlowCharting这是什么么工具?What is thetool?过程的图图像描述述Graphicalillustration of theprocess工具要描描述的是是什么?What willthe toolidentify?所有增值值和不增增值的

12、过过程步骤骤Allvalue-addedand non-value-addedprocess steps识别系统统设计和和再设计计的机会会Identifyopportunities forSystemDesign/redesign关键输入入KeyProcessInputs(xs)关键输出出KeyProcessOutputs (Ys)数据采集集点Data CollectionPoints输入FMEA的第一批批输入参参数FirstKeyprocessinputvariablestoput in FMEA什么时候候制作过过程流程程图?When do youapplyprocess mapping?一

13、直Always制作过程程流程图图的结果果是什么么?What areresults of ProcessMapping?看建议的的新的设设计或再再设计是是不是比比现有系系统好Identifywhether proposed newsystemdesign/redesignisbetterthencurrent system识别需要要测量系系统研究究的系统统Identifysystems needingMeasurementStudies识别需要要能力性性研究的的关键输输出IdentifyKeyprocessoutputs forCapability Studies识别控制制计划中中缺的项项Ide

14、ntifymissing elements in theControl Plan识别过程程中不增增值的步步骤Identifypossiblenon-value-addedprocessstepscustomerNoYesNoYes案例分析析:制作流程程图Case Study:FlowChartingFulfill Order跨职能流流程图(泳道图)CrossFunctional Map(SwimLane)是一种描描述不同同职能或或部门之之间的连连接关系系A mapthat conveysprocesshand offsbetweenfunctionsordepartments把流程图图中的步步

15、骤重编编排成按按职能排排的泳道道Rearranges flowchartprocessstepsinto lanes of functions行或列代表表职能Rows or columnsrepresent functions不同活动归属属不同的的职能带带Activities fallinappropriate“bands”offunctions同时发生的活活动从上上到下归归组Concurrent activitiesgrouped“top to bottom”有时也被称为为职能图图或泳道道图Sometimescalled “Functional”or“SwimLane”flowchart o

16、r mapFunction 1Function 2Function 3Function 4过程步骤骤按时间间顺序从从左到右右Process steps movelefttorightastime progresses明确显示示部门之之间的交交接Clearly shows hand-offsbetween departments or groups也称为泳泳道图或或职能图图Also known as a“SwimLane”orsometimes “Functional Map”案例分析析:制作跨职职能流程程图Case Study:CrossFunctionalMapping (cont.)Ful

17、fill Order跨资源图图CrossResourceMap是一种描描述系统统或组织织内资源源传递的的图A mapthat conveysprocesshand offsbetweenindividual resourcesina systemororganization行或列表示示各个资资源Rows or columnsrepresent individualresources各项活动归归属不同同的资源源带Activities fallinappropriate“bands”ofresources同时发生的活活动从上上到下归归组Concurrent activitiesgrouped“to

18、p to bottom”显示资源传递递Showshandoffs,resources involvedFunction 1Function 2Function 3Function 4Resource 1Resource 2过程步骤骤按时间间顺序从从左到右右Process steps movelefttorightastime progresses明确显示示资源之之间的传传递Clearly shows hand-offsbetween resources经常同时时显示职职能和资资源OftenshowsbothFunctionsandResources只是低一级的的跨职能能图Just across

19、functionalmapatalowerlevel制作跨资源图图的步骤骤CrossResourceMapping Steps始于流程图图或跨职职能图Startwith FlowChartorCrossFunctionalMap识别过程所接接触到的的资源并并把它们们记录在在纸的左左侧Identifyindividual resourcesthat theprocess touchesand recordonleft sideofpage画泳道线把把资源分分开Draw lines to representthelanesbetweenresources从图的左侧侧开始,把流程图图中的第第一步放放

20、在合适适的泳道道里Startonleft sideofmap,placefirststep fromflowchartinappropriatelane继续把其余的的过程步步骤按以以下的规规则放在在泳道里里Continuetoplaceprocess steps accordingtofollowingguidelines时间从左到右右上升Time increasesfrom lefttorightacross map同时发生的步步骤应上上下叠在在一起Stepsthat occur simultaneously shouldbestacked on topofeach other箭头总是左进进

21、右出Arrowsalways exitonrightand enter on leftsidesofprocesssymbols互相连接的但但至少相相隔一个个泳道的的步骤应应用虚线线连接Processesthatareconnected,butare morethanonelaneapartshouldbeconnected withdotted lines案例分析析:制作跨资资源图Case Study:CrossResourceMapping(cont.)Fulfill Order跨资源图图CrossFunctional /Deployment MapCUSTS MGRTECHMECHCAS

22、HDATA BASESAWRITESCOMPLAINTNOTIFIESCUSTOMERSCHEDANALYSISANDREPAIRREVIEWS COMPLAINTANDSPECIFIES REPAIRREPAIRS VEHICLECOMPLETESINVOICEENTERSJOB IN WORKLOGARRIVES AT DEALERWAITSINLOUNGEPAYS CASHIERDDVEHICLE DATADDAutomobile RepairProcess带时间的的跨职能能图CrossFunctionalMapwithTimeCustomerSalesProductionControl

23、PlantAWarehousePlantBTransportProcess OrderPrintorderorderMoveWIPExtrudeProductProductReceive ProductProduct50daysFunctionsProcess TasksNon-Value-AddedTimeTimeDirectionofProcessFlowWaitWaitWaitMoveWaitMoveWIPWIPWIPWIPWIPOrderProduct数据流-实体流的的泳道图图Data FlowPhysicalFlow SwimLaneChartProcessInitial Order

24、EntryTrip PlanGenerationShipmentMgmtOutput/MeasureEmptyCarFulfillmentDataFlowPhysicalFlow- AccountManagement PhysicalFlow-PricingPhysicalFlow-OrderManagementPhysicalFlowShipmentManagementPhysicalFlow-SettlementFLOW:CurrentProposedXEventOccasionsTime/DistanceDefineUnitsCostTotalsTotalFloorspace_sq,ft

25、,ValueAddedIndex:(B/D)x 100%1.53 %DeliveryIndex:(A/C)x 100%1.53 %Process:_SamplePart_Business:_Miscellaneous Machining_过程流程程图Flow ProcessChartCharted By:_HenriettaSmith_Date:_12/19/03_OperationorProcess Recordtime/unit.Delay(Re-work,Changeover,Wait)Recordtype,averagedurationandfrequency.Tabulateperu

26、nitvalue.Inspection Tabulate duration andfrequency.Tabulateperunitvalue.Transport Tabulate distance moved andquantitymoved.Storage/Inventory Tabulate averageQuantityinstorageorqueue(A)(B)(C)(D)ReceivingDock/ShippingDock1000 units1000 units0.5hours4 hoursPPIStagingPPIInspection2 hours250units48hours600unitsDept.AStaging1 hour250units3 hours100unitsMachine 1C/T=0.5hours10unitsMachine 2C/T=0.5hours10units0.5hours10units41312C/O1 hourCost/Hr.= $80”= 25 ft.1 hour1 hour56hours2600 units2 hours250units5 hours$80$80$4480$160$400$52004 hours1000 units65hoursDEPT APP