【文章內(nèi)容簡介】 x浪費 1 運輸 Machines Next to Each Other…Transport Time Minimized 將機臺放在一起，運輸時間降到最低 LEAN TO EXCELLENCE 19 浪費 2 庫存 Waste Asks For More Waste庫存浪費會產(chǎn)生更多浪費 High spoilage高損壞率 Poor product quality品質(zhì)問題 Slow running 生產(chǎn)緩慢 Frequent breakdowns 頻繁的中斷 Long changeovers長換線時間 庫存高度 Unplanned stoppages 無計劃停線 ? Ties Up Working Capital 使營運資金緊張 ? Takes Valuable Space占用可用空間 ? Risk of Obsolescence呆料風險 Inventory levels LEAN TO EXCELLENCE 20 c l i m b i n gs i t t i n g???s e a r c h i n gt u r n i n g a r o u n dwa l k i n gc h o o s i n gb e n d i n go v e rl y i n g d o w nBefore改善前 After改善后 Treat Operators as Surgeons…Everything Within Reach 視訓練作業(yè)員如同外科醫(yī)生 … 每件東西都放在手所及范圍內(nèi) 浪費 3 動作 ? Ergonomic Concerns人體工程學考量 ? Labor Efficiency勞動效率 ? Wasted Cycle Time 浪費周期時間 LEAN TO EXCELLENCE 21 浪費 4 等待 When Inventory Waits Your Customer Waits當庫存在等待時，客戶也在等待 ? Increases Lead Time增加制造周期 ? Increases Work in Process增加流程中在制品 ? Slows Response to Customer對客戶反應慢 LEAN TO EXCELLENCE 22 浪費 5 過量生產(chǎn) Do Not Produce What the Customer Does Not Need 不要生產(chǎn)客戶還不需要的東西 ? Ties Up Working Capital使營運資金緊張 ? Takes Up Floor Space占用空間 ? Hides Process Problems隱藏流程中的問題 LEAN TO EXCELLENCE 23 ?Creates Delay產(chǎn)生延遲 ?Increased Opportunity for More Defects增加錯誤機會 ?Doesn?t Add Value By Definition不能增加價值 浪費 6不必要的過程 Match Physical Movement With Systemic Transaction…Strive for 1:1 Ratio 盡量將實物流動與系統(tǒng)處理匹配，目標比例是 1:1 Manual Entry of Information人工輸入信息 LEAN TO EXCELLENCE 24 ? Upsets Customers讓客戶不滿意 ? Consumes Resources消耗資源 ? Chokes Flow堵塞流程 浪費 7缺陷 Reworking Defects Is Wasteful…Sending Them to Customers is Outrageous 返工不良就是浪費 … 把這些貨送給客戶是不允許的 LEAN TO EXCELLENCE 25 Skills not Utilized未被用到的技能 7+1浪費 未被用到的技能 ? Unutilized resources of skill/knowledge from the shop floor worker 現(xiàn)場工人未被利用的技能 /知識 LEAN TO EXCELLENCE Value Stream Mapping (VSM) 價值流程圖 Current State Map現(xiàn)狀圖 Future State Map 未來圖 LEAN TO EXCELLENCE 27 TOTAL Value Stream完整價值流 供應 商 工廠 /服務維修站 客戶 什么 是價值流？ See the Whole Process from Start to Finish 從源頭到末端看整個價值流 LEAN TO EXCELLENCE 28 Process Level 流程等級 Single Plant ( door to door ) 單個工廠（門到門） Multiple Plants 多個工廠 Across Companies 包含整個公司 流程圖 等級 Can Be Used at Any Level in the Business可運用在任何等級 LEAN TO EXCELLENCE 29 ? Understand current situation Big picture point of view 了解現(xiàn)況 查看全局 ? Shows the ratio of NonValue Added to Value Added Time 顯示非價值增加與價值增加活動的比例 ? Exposes sources of waste not just waste 暴露出浪費 源 —并非只有浪費 ? Shows linkage between the seven types of flow 顯示 7種流程之間的聯(lián)系 為什么 要畫價值流程圖？ Forms the Blueprint for a Lean Implementation Plan 建立 Lean 執(zhí)行計劃的藍圖 LEAN TO EXCELLENCE 30 Product Family 產(chǎn)品系列 Implementation Plan實施計劃 Current State Drawing現(xiàn)狀繪制 Future State Drawing未來狀況描繪 2 3 4 1 ?Identify the Value Stream for every major product family / program定義每個主要產(chǎn)品系列 /程序的 價值流 Concept to launch Order to delivery 產(chǎn)品投放概念 – 訂單交貨 ?Map the current state Identify all the actions that don‘t create value (VA/NVA/VE) 繪制現(xiàn)狀流程圖 – 定義所有 不能增加價值的活動 (VA/NVA/VE) ?Develop and map concepts for the future state as a Management team municate your vision to your team. ?像一個管理團隊一樣，發(fā)展和描繪未來藍圖，并與你的組員溝通你的想法 ? Develop metrics determine goals …How will Success be measured? ?展開矩陣及制定目標 … 目標達成如何測量？ ? Develop actions and drive toward future state ?制定行動計劃并努力朝未來邁進 我們 如何開始？ LEAN TO EXCELLENCE 31 The 7 Types of ?FLOW‘ 7種類型‘流程’ 5. People 人 Std Work 標準工作 Takt Time 節(jié)拍時間 1. Material – Raw 物流 原材料 2. Material – WIP 物流 在制品 3. Material – Finished Goods物流 成品 6. Equipment 設備 Carts推車 conveyors 傳送帶 Andons 信號燈 racks貨架 TPM全面生產(chǎn)維護 4. Information 信息流 Act on Material 物料加工處 Load into machine 設備上料處 Move it from 1 bucket to another 從一個地方轉(zhuǎn)移至另外的地方 7. Engineering/Tools工程 /工具 Quality品質(zhì) Tooling工具 cutting tools 切削工具 Programs 程序 The Problems as well as the Answers Lie Within the Flow 問題 和 答案 都展現(xiàn)在流程里 我們 可以看到什么？ LEAN TO EXCELLENCE 32 ? Start at the customer and work backwards 從客戶開始逆向開始工作 ? Walk the actual flows 跟著實際流程走線 ? Don?t Map the Organization but the flow through it 不需要畫出組織，但會體現(xiàn)在流程中 ? Don?t be too detailed this is an overview 看全局，不需太細節(jié) ? Use pencil not power point…quick and crude 不使用電腦，而是用鉛筆畫出來，快速而直接 指導 方針 Pretend you are the ?Product? …And follow the path ?product? flows 假設你就是這個‘產(chǎn)品 ?， … 就跟著這個 ?產(chǎn)品 ?的腳步走吧。 LEAN TO EXCELLENCE 33 現(xiàn)有 /最初狀況流程圖 KITTING Vendor Managed Inventory (VMI) Customer Forecast 3mo Firm Biweekly Forecast Firm Order Kitting Racks SMT/ICT LINE Finished Goods Store 1 h** 12 Day Ship AVG TAKT TIME* Mod 1: 194 sec/pc L5: 415 sec/pc Pick List 36 hrs BAX CONVERSION BOTTOM Yield=99.% Yield=% TOP Yield=% MIDDLE** Yield=% BACKEND LEVEL 5 LEVEL 3 Traffic Intersection Daily Schedule Pack Plan Daily Schedule On Demand Loading Plan weekly daily Kits Daily Tra