企业职业培训22价值流图析

ValueStreamMapping

价值流图析PartI:CurrentStateMapping第一部分：现状图ProductionControlSchedulingCustomer客户Suppliers供应商Purchasing?Materials?Manpower?PriorityManpowerAvailableDelayMakePartsPaintDeptMaterialAvailableDelayExpediteStorageStorageNeedPartsProcessMappingBenefits

过程图的优点Obtaincurrentplantoperatinginformation获得当前车间的业务资料Obtaincurrentmetricsinformation获得当前的数据资料Identifiesinventoryandwhereitisstored区分在库及其地点Showsmaterialflow表明原料的流动Givesyouabaselineonwhereyouareandatooltochartyourprogressafterimplementingimprovementswithintheplant在车间内实行改进后，给你一个绘制你进步的基点和工具ObjectivesforValueStreamAnalysis

价值流析的目标Understandthebenefitsofprocessmapping理解过程图的优点Developaprocessmapusingicons用图标来绘制过程图Understandhowtheprocessmapwillbeusedtodevelopcurrentstatebaselines,stretchobjectivesandimprovementactions理解怎样用过程图来发展当前状态基线，展望远景和改进行为。Aging9天周计划礼拜四礼拜二/礼拜四2天15天3天(0.5天)3天钢铁供应商礼拜一/三/五压合工程热合工程顾客B顾客A生产控制每月订单3件产品7天-3班/星期批量生产-1个星期的量转换时间-4小时转换的频率-7个班不良率-7%停机时间比率-11%“Y”Avg.strokes/hour月需求量-18,000节拍时间=60”理想周期=360”不良率-3%重修率-20%停机时间比率10%2hrsOT56件/月-人月需求量-18,000生产时间–450分钟每班2班20天每个月节拍时间=60”理想周期=240”不良率-7%重修率-12%9件/月-人制造工程焊接工程ExampleofaCurrentStateMap9天9天Definition定义AValueStreamisthecollectionofallactivitiesrequiredtoproduceaproduct.

Thisincludesallactivities,includingthosethataddvalueandthosethatdonot.价值流是制造产品所必需的全部活动的集中。这就包括了产生价值和不产生价值的全部活动。TheBIGPicture整体性Usingthevaluestreamanalysismeansworkingonthebigpicture,notjusttheindividualprocesses;improvingthewhole,notjustoptimizingtheparts.运用价值流分析意味着在整体上工作，不仅仅是个别的生产过程；不只是优化局部而是提高全部。OurScope我们的范围Forthislesson,wewillbefocusingonthe“door-to-door”productionflowinsideourplant.ThatincludesReceivingandShipping.这里我们将把重点放在工厂车间与车间的生产流程上面。它包括接收和货运TotalValueStream价值流OurFocus重点Suppliers供货商OurPlantand/orCompany车间或公司Customer顾客OurScope(cont’d)我们的范围（续）Asyourexperiencegrows,youcanexpandoutwardtoincludetheflowfromsupplierstocustomers.随着经验的增长，你能够向外扩展到包括从供货商到消费者的连续流。Likewise,oureffortswillnotgetintothedetailsofeachdepartments’specificsofoperation.同样的，我们的重点不会陷入获取每个部门详细的操作细节。Thisisnotacomputerprocess

这不是一个使用计算机的过程ValueStreamMappingisapencilandpapertoolthathelpsyoutoseeandunderstandtheflowsofmaterialandinformationasaproductmakesitswaythroughthevaluestream.价值流图是以笔和纸为工具来帮助你在产品通过价值流时看清和理解物料和信息的流向。MaterialandInformationFlow

材料和信息流Themovementofmaterialisusuallywhatcomestomindwhenwediscuss“productionflow”.当我们谈论产品流程时，通常想到的是材料的流动。Butthereisanotherflow-ofinformation-whichtellseachprocesswhattomakeordonext。但还有一种-信息流，它能告诉你每个过程做什么和将要做什么。Youmustmapbothofthem.你必须同时图析他们ProductionFlowinformationmaterialUsingtheMappingTool

运用图析工具First,wedrawthecurrentstatemapbygatheringinformationdirectlyfromtheshopfloor.首先，我们应运用从车间直接采集的信息来绘制现在状态图。ProductFamily产品系列CurrentStateDrawing现状图FutureStateDrawing将来图WorkPlan计划UsingtheMappingToolFromthis,webegintodrawourideal,orimproved,operation;ourFutureStateMap.从这里我们开始画理想和改良的操作；我们的将来状态图。ProductFamily产品系列CurrentStateDrawing现状图FutureStateDrawing未来状态图WorkPlan工作计划UsingtheMappingToolThefinalstepistoimplementaplantotransitiontheplantfromthecurrentstatetothefuturestate.最后的步骤是执行从现在到将来状态工厂转变的计划ProductFamilyCurrentStateDrawingFutureStateDrawingWorkPlanFocusononeProductFamily

重点在一种产品Drawingallyourproductflowsononemapwilltoocomplicated.在一幅图里画出所有的产品太复杂。ValueStreamMappingmeanswalkinganddrawingtheprocesssteps(materialandinformation)foroneproductfamilyfromdoortodoorintheplant.价值流图析意味着从工厂的一个车间到另一个车间画出一种产品的生产步骤。 DrawingaCurrentStateMap

绘制一幅现状图Mappingbeginsatthelevelofdoor-to-doorflowinyourplant.在你的工厂里门对门的流动水平下开始绘图。Processingcategoriesareidentifiedratherthanrecordingeachandeverystep.过程种类的确定远胜于每个步骤的记录。“Cutting”,“Welding”,“Stitching”切割，焊接，缝纫。TheIconsUsed.所用图标Weusesymbols,oricons,torepresentprocessesandflow.我们用标记，图标来代替过程和流。制造合作公司_hour_hour__/wk数据框在库及数量成品向顾客的流动原材料在厂内的流动顺序生产流公路运输(每周几次)运输途径(多长时间)原材料被下个工序拉动指导生产信息流ABC(产品)市场Aging必须在库时间手工信息流电子信息流DrawingtheCurrentStateMap

绘制现状图AnExample:一个实例：AcmeManufacturingproduceswidgets.Thewidgetsareproducedintwoversions:style-type“A”andstyle-type“B”.TheAstylehasaleft-handmountingbracketandtheBstylehasright-handmountingbracket.Thereisnovariabilityinthedesignbeyondtheversionsofthemountingbracket.阿克米加工厂生产以中小部件。有两种型号：A和B型。A型有一个左侧的支架，B型有一个右侧的支架。除了左右侧之外，该产品在设计上没有区别。Beginwiththecustomer’srequirements.以顾客的要求开始Thecustomer’sassemblyplantisrepresentedwithafactoryiconplacedintheupperright-handportionofthemap.Underneath,drawadataboxrecordingtherequirementsofthecustomer.客户的公司以右上角的符号标志，下面画一个数据框来记录客户的要求。AltonaAssembly公司两班生产，每天都需要运输产品。一般每月需求12,000A和6,400B.StateStreetrequestspalletizedreturnabletraywith20bracketsinatrayandupto10traysonapallet.18,400件/天-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.下一步是绘制基本生产过程。我们用一个过程框来表示一个过程。在每个过程，我们在数据框里写下重要信息：周期时间，换型时间和可靠性。Asyouwalkthematerialflowyouwillfindplaceswhereinventoryaccumulates.Thesepointsarewheretheflowisstopping.Weindicatethiswithtombstonestoindicate“dead”flow.ShowProcessesinourplant绘制工厂里的各个过程22,000pcs/day-14,000“A”-8,000“B”Tray=20pieces2shiftsAltonaAssembly18,400pcs/day-12,000“A”-6,400“B”Box=20pieces2shiftsIncludethesuppliers包括供应商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=20pieces2shiftsTheInformationFlow信流TheProductionControlDepartmentisdrawnwithaprocessbox.用一个过程框表示生产管理科。ProductionControlcollectsinformationfromitscustomersandsendsspecificinstructionstoeachmanufacturingprocessaboutwhatitshouldproduce.生产管理可从客户那里收集信息并下达详细的生产指令给每一个生产过程，告诉他们应生产什么。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洗涤Assembly组装Shipping发货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生产管理Forecast预报Weekly周Forecast预报Weekly周WeeklySchedule周进度DailyShipSchedule每天发货计划1xDaily18,400pcs/day-12,000“A”-6,400“B”Box=20pieces2shiftsAddLeadTimes加上生产周期TransferWasherAssemblyShippingRawHsg5daysC/T=20secC/O=1hrUptime:65%C/T=10secC/O=0Uptime:95%C/T=61secC/O=10minUptime:100%20,000A15,000B25,000A18,000