【正文】 gging) 14 Value Stream Mapping Define Step 1: SIPOC Business Requirements ? Not only should the SIPOC chart capture customer requirements, but also the key Business Requirements as well. O U T P U T PROCESS C U S T O M E R S U P P L I E R I N P U T Customer Requirements ?Quality ?Ontime Delivery ?Cost Business Requirements ?Reduced Inventory ?Increased Throughput 15 Value Stream Mapping Measure Analyze Control Improve Define Step 1 SIPOC Chart ?BD Industries Exercise Measure Analyze Control Improve Define Step 2 Top Down Process Flow Define Step 2: TopDown Process Flow Purpose ? The purpose of the TopDown Process Flow is to determine the correct level to Value Stream Map. ? It is critical to our business to focus our improvement resources on the areas that are going to have the greatest return. ? We do not want to create Value Stream Maps for the sake of creating pretty pictures. 18 Value Stream Mapping Define T h e P r o c e s s The SubProcess The MicroProcess Step 2: Generic TopDown Process Flow 19 Value Stream Mapping Define Distribution Pump Motor Foundry Example: Step 2: TopDown Process Flow Map Start Stop D1 D2 D3 D4 D5 D4a D4b D4c D4d D4e 20 Value Stream Mapping Measure Analyze Control Improve Define Step 3 Determine Product Family to Map Define Step 3: Determine Product Family to Map ? Choose the product family that has the greatest impact on the Customer Outputs, and the Business Requirements. ? Choose a product family with mon flow. ? Choose a product family with high volume. ? Choose a product family based on customer industry, or other product segmentation. ? If a product family is not readily apparent (such as in a job shop environment), use a process/product matrix to identify a product family. 22 Value Stream Mapping Define Step 3: Process/Product Matrix ? Products and Process Matrix ? Create a matrix of products and processes (equipment) through which they pass. ? Reference routers if necessary but ensure they are verified and not assumed to be accurate. ? Group similar products together. R e c e i v i n g S t a m p i n g D r i l l Mill G r i n d D r i l l P r e s s P a i n t C u r e P a c kA x x x x x x x x xB x x x x x x x x xC x x x x x x x x xD x x x xE x x x xF x x x x xG x x x x xProductsP R O C E S S E S23 Value Stream Mapping Measure Analyze Control Improve Define Step 4 Draw the Process Flow Define Step 4: Draw the Process Flow Tips: ? Begin at the end of the process (shipping) and work upstream ? Determine where material and information is used along the process ? Map the entire process as a team to understand the entire flow ? Draw Value Stream Maps by hand to get it done quickly, and make it easy to change Lessons Learned: ? Get alignment on start and end of value stream before beginning map ? Be mindful of processes that are in parallel vs. series ? Capture all rework loops and inspection stations on the map ? Limit the value stream to just one product family 25 Value Stream Mapping Define Step 4: Sample Symbols Machining Process Box Data Box I Inventory 1 Operator Manual Information Electronic Information C/T = 36 Sec Set Up Time 7 Min Uptime 86% Batch Size 50 Inspection Point Withdrawal Kanban Push Arrow Customers / Suppliers To Customer Production Kanban Supermarket Truck Shipment Future State Improvement “ Go See” Scheduling Daily Schedule Schedule 26 Value Stream Mapping Define Step 4: Value Stream Mapping Sheets 27 Value Stream Mapping Define Step 4: Draw the Process Flow Production Control ASSEMBLY CUSTOMER Production Control MACHINE SUPPLIER DIST 28 Assembly Assembly Fe Machine ?Raw material ?Daily schedule ?Fe material ?Daily schedule ? Bolts, nuts, washers ? Daily schedule ?Oring, bearing, snap ring ? Daily schedule 28 Value Stream Mapping Define Supplier Raw Materials MRP transaction Receiving Inspection Receiving 1 Unpack Bottles Unpack 1 Bottle Washer Washer 1 Fill Cap Fill 1 Heat Shrink Sealer 1 Labels on Bottles Labeler 1 Pack Product Drop Pack 1 Labels on Package Label 1 Tag Crate Pallet 1 Shrink Wrap Load Ship 1 Distribution Center Customer 888 Cases/Day 37 Cases/Hr I Bottle Kits 16 days I Warehouse I I I I Step 4: Process Flow Liquid Pharmaceutical Current State VSM 29 Value Stream Mapping Measure Analyze Control Improve Define Step 4 Draw the Process Flow ?BD Industries Exercise Define Step 4: BD Industries Exercise ? Complete the following steps using the information from BD Industries: ? Current State Process Flow ? Material required at each process step ? Information required at each process step Time: 1 Hour 31 Value Stream Mapping Measure Analyze Control Improve Define Step 4 Draw the Process Flow ?Flygt Activity ?2 Hours Measure Analyze Control Improve Define Step 5 Draw the Material Flow Define Step 5: Draw the Material Flow ? Show the movement of all material used in the Value Stream. ? Group material with the same flow. ? Map all subassembly processes. ? Include any ining inspection, and material testing operations. 34 Value Stream Mapping Define Step 5: Draw the Material Flow Production Control ASSEMBLY SUPPLIER DIST Assembly Assembly Fe Machine ?Raw material ?Daily schedule ?Fe material ?Daily schedule ? Bolts, nuts, washers ? Daily schedule ?Oring, bearing, snap ring ? Daily schedule Warehouse Receiving Customer 35 Value Stream Mapping Define Supplier Raw Materials MRP transaction Receiving