【正文】 5/7/2023 1Value Stream Mapping 值流繪圖Kaizen!Action Resp When Benefit我該如何開始LEAN訓(xùn)練？5/7/2023 2VSM介紹LEI和 TSSC的源由VSM的歷史VSM目的介紹 VSM，讓學(xué)員在工作上能應(yīng)用 VSM建立值流圖，提供有用的信息給主辦單位發(fā)展學(xué)員鑒別值流中浪費(fèi)的能力幫助學(xué)員了解， LEAN工具如何結(jié)合，來協(xié)助我們達(dá)成工作目標(biāo)歡迎隨時(shí)發(fā)問 !5/7/2023 3第一章 – 值流繪圖程序Value Stream Mapping5/7/2023 4什么是 VSM？什么是值流？值流包括了完成某一種產(chǎn)品或服務(wù)所必須要的所有 程序步驟 (加值和非加值 )什么是值流繪圖？值流繪圖是一種將 物流 和 信息流 可 視化 的方法，用以協(xié)助我們完成產(chǎn)品或服務(wù)5/7/2023 5值流改進(jìn) 過程改進(jìn)值流 =由原材料開始到交貨給顧客，所需要的步驟，包括加值和非加值的步驟Value Stream值流STAMP壓字MACHINE車削ASSEMBLE裝配PROCESS 過程 PROCESS 過程 PROCESS 過程RawMaterial 原料 FinishedProduct 成品Customer顧客5/7/2023 6值流的描繪跟隨產(chǎn)品 從 結(jié)束 回溯至 開始 的生產(chǎn)過程，并 利用 物流 和信息流 的圖標(biāo) (現(xiàn)況圖 )來描繪出 可目視 的圖像接著繪出未來圖，以顯示應(yīng)有的 價(jià)值流動(dòng)5/7/2023 7Information FlowP/T 1226 s DistributiondailySewing3ShippingFinal Assembly2I1800 pcs Suppliers.Fabric WeeklyOther BiWeeklyProduction ControlWeeklyOrders5 weekForecastWeeklyOrdersWeekly ScheduleDaily ShiplistFabric Fabric Cut3000 pcs 650 pcsUpholstry6 295 pcs 600 pcsFrame AssyFoam AssyI2023 pcs 800 pcs 785 pcsFramesMCT = 60 secC/O = 20 min OCT = 150 secC/O = 2 minOCT = 501 secC/O = 0 minOCT = 395 secC/O = 0 minOCT = 60 secC/O = 0 minOCT = 60 secC/O = 0 minI I I I1000 chairs/wk1 ShiftIIFlow Racks F/G WarehouseTicketsMaterial Flow10 d 120 s 15 d 4 d d 3 d L/T d 210 s 501 s 395 s TimelineT/T=135s5/7/2023 8第二章 – 建立現(xiàn)況圖Value Stream Mapping5/7/2023 9 “高地公司 ” 生產(chǎn)制造的數(shù)據(jù)表實(shí)例研究的數(shù)據(jù)表在手冊的附錄 D利用 “ 高地公司 ” 的數(shù)據(jù)表做實(shí)例研究檢討5/7/2023 10 Manchester Avenue1x daily18, 400 pcs/mo12,000 “L”6,400 “R”Tray = 20 pcs2 shiftsTT = 60 sec.5/7/2023 11在制程前或后有庫存在倆制程間沒有實(shí)現(xiàn)一件流 .交接如果是一件流交接 , 就不要增加另一個(gè)制程方框如果 職能 之間的交接打斷了流程 , 就要增加制程方框 確定過程方框5/7/2023 12ManchesterAvenue1x dailyStamp Machine Weld SubAssembly Assembly Shipping18, 4000 pcs/mo12,000 “L”6,400 “R”Tray = 20 pcs2 shiftsTT = 60 sec.SR5/7/2023 13ManchesterAvenue1x daily18, 4000 pcs/mo12,000 “L”6,400 “R”Tray = 20 pcs2 shiftsTT = 60 sec. Stamp Machine Weld SubAssembly Assembly ShippingSR5/7/2023 14Data Box Process Box Definitions And SymbolsThe Below Data Gets Added To Or Above the Process Box下列數(shù)據(jù)記錄于程序盒內(nèi)或上方Shared Resource (Shared if the resource is used by other value streams) 共享資源 ………………………………………. SRNumber Of Operators 操作員人數(shù) …………………………………………………………………………………………… = Number Of Shifts This Process Is Run 執(zhí)行此程序時(shí)的班別數(shù) ……………………………………………………………….. SH = Takt Time ( Shown one time in/near the customer Data Box) 客戶需求時(shí)間 ………………………………………..………… T/T = TimeNote: The Following Information Goes In the Data Box below the Process Box下列信息記錄于程序盒下方的數(shù)據(jù)盒內(nèi)Operator Cycle Time 操作員周期時(shí)間 ………………………………………………………………………………………… OCT = TimeMachine Cycle Time 機(jī)器周期時(shí)間 …………………………………………………………………………………………… MCT = TimeDrop Off Rate (How often a finished part is pleted off the end of the process) 產(chǎn)出率 ………………….…...………….. D/R = TimeProcess Lead Time (Time required to plete a batch through a process) 程序前置時(shí)間 ……………………...…………… PLT = TimeBatch Size (Size of the batch through a process when greater than one piece) 披量 ……………………..……...…… … …… BATCH = PiecesProcess Time Per Piece (Process leadtime divided by batch size) 單件程序時(shí)間 ………………………………..…………… PTP = TimeReject Rate (Percent of product that is rejected for quality defects) 不良率 ………………… … …………..……..….…….. REJ = %Uptime (Percent of planned time the process runs, takes out breakdowns unplanned maintenance) 操作率 …...…………… U/T = %Changeover Time (Time to change from the last good piece of part A to the first good piece of part B) 換模時(shí)間 …............ C/O = TimeEvery Part Every_____ (How often every part number is run through the process, Setup Wheel)生產(chǎn)循環(huán)時(shí)間 ... ............ .....EPE = TimePitch Interval (How often the container quantity is pleted) 間距時(shí)間 ………………………………………...……..…... PITCH = TimeProcess Boxt程序盒NOTE: Only place appropriate data in the data box.The list above may not be totally inclusive.Data Box資料盒數(shù)據(jù)盒只記錄實(shí)際需要的數(shù)據(jù)，不一定要記錄上面的全部信息5/7/2023 15This is a manual process. Assembly, manual machining, load/unload… Put this time into the Process Capacity Chart under OCT to calculate the capacity of this operation. 這是人工時(shí)間，例如：裝配、人工車削、上料 /下料 ...。這一類的時(shí)間，在計(jì)算此一加工作業(yè)的產(chǎn)能時(shí)，被歸類為程序產(chǎn)能表的操作員周期時(shí)間。OCT 操作員周期時(shí)間TimeMCT 機(jī)器周期時(shí)間This is an automatic process. Stamping machine, automatic molding machine, milling… Put this time into the process capacity chart under MCT to calculate the capacity of this machine這是機(jī)器時(shí)間，例如：壓字機(jī)、自動(dòng)鑄模機(jī)、研磨 ...。這一類的時(shí)間，在計(jì)算此一加工作業(yè)的產(chǎn)能時(shí)，被歸類為程序產(chǎn)能表的機(jī)器周期時(shí)間。TimeOCT 操作員周期時(shí)間 MCT 機(jī)器周期時(shí)間This is a manual process triggering an automatic process. Loading time + automatic time, test equipment, manual unload and restart of diecast… If the operator can be separated from the machine, record the OCT and MCT on separate lines. If the operator is tied to the machine, put the total time (OCT+MCT) in the process capacity chart.這是人工過程觸發(fā)機(jī)器過程，例如：上料時(shí)間 +機(jī)器加工時(shí)間、測試設(shè)備、人工上料并開始壓鑄 ...。如果能夠?qū)⒉僮鲉T與機(jī)器分離，就要把操作員周期時(shí)間和機(jī)器周期時(shí)間記錄在不同的軸在線。如果無法將操作員與機(jī)器分離，就把總時(shí)間 (操作員周期時(shí)間 +機(jī)器周期時(shí)間 )記錄在程序產(chǎn)能表上。TimeDefinition Of Processes And Times 程序和時(shí)間的定義5/7/2023 161x daily18, 4000 pcs/mo12,000 “L”6,400 “R”Tray = 20 pcs2 shiftsManchesterAvenueOCT = 40 secD/R = 40 secC/O = 0REJ = 7%U/T = 100%2Shifts27,600 sec. Avail.1TT = 60 sec.Stamp Machine Weld SubAssembly Assembly ShippingSR5/7/2023 17ShippingManchesterAvenueMCT = 1 secondC/O = 1 hourREJ = 3%U/T = 85%EPE = 2 weeks27,600 sec. AvailStamp1x dailyMachine1Weld1SubAssembly1Assembly1OCT = 39 secD/R = 39 secC/O = 10 minREJ = 4%U/T= 100%2 Shifts27, 600 sec Avail