【正文】 s 1H ChartItemTime048121620240%20%40%60%80%100%048121620240%40%70%100%120%150%Next ProblemSelectionIshakawa Diagram(. Fishbone or Cause Effect)Why is Fat Rabbit Happening?Detail Flow Chart of ProcessRoot CauseBefore and After ParetoPositive/Negative Side EffectsRun ChartSolution Implemented4 W39。In Coming 改善過(guò)分精確的加工或多余的加工，造成不必要的浪費(fèi)動(dòng)作的浪費(fèi)物品取放，反轉(zhuǎn)，對(duì)準(zhǔn)等不合理；作業(yè)是轉(zhuǎn)身，大幅度動(dòng)作；抬臂過(guò)高，過(guò)低；頻繁的走動(dòng)。MinMax 系統(tǒng)采購(gòu)或保持不需要的原材料、在制品、成品Min MaxProcess A Process B制造不良的浪費(fèi)材料損失；設(shè)備，人員工時(shí)損失；影響生產(chǎn)；出貨延誤；產(chǎn)品降價(jià)；檢查等級(jí)高；工作沒(méi)規(guī)律。圖析幫助你發(fā)現(xiàn)價(jià)值流中浪費(fèi)的根源；它將精益概念和技術(shù)結(jié)合起來(lái)，幫助你避免 “揀櫻桃 ”；它可以顯示信息流和材料流的聯(lián)系，沒(méi)有其他工具能作到這點(diǎn)它比做出非增值步驟、生產(chǎn)周期、移動(dòng)距離、庫(kù)存數(shù)量等清單的定量工具和生產(chǎn)布局圖更為有效；更重要的是價(jià)值流圖將供應(yīng)商 — 企業(yè) — 客戶之間的活動(dòng)聯(lián)系在一起，形成簡(jiǎn)單、清晰的價(jià)值鏈，可以一目了然地發(fā)現(xiàn)企業(yè)經(jīng)營(yíng)活動(dòng)中存在的問(wèn)題。精益價(jià)值流Value Stream Management目錄一 ：精益價(jià)值流簡(jiǎn)介二 ：產(chǎn)品價(jià)值流圖三 ：企業(yè)價(jià)值流圖四 ：價(jià)值流管理精益的概念只需要：一半的工人；一半的制造空間；一半的工具投資；一半的設(shè)計(jì)工時(shí)；一半的新產(chǎn)品開(kāi)發(fā)時(shí)間；一半的庫(kù)存；一半的產(chǎn)品前置時(shí)間生產(chǎn)出品質(zhì)更好、數(shù)量更多的產(chǎn)品。價(jià)值流圖示步驟由此進(jìn)入形成規(guī)范化并持續(xù)改善實(shí)現(xiàn)未來(lái)價(jià)值流并予以獎(jiǎng)勵(lì)制定正確的執(zhí)行計(jì)劃選擇價(jià)值流圖析產(chǎn)品理解并應(yīng)用精益工具繪制現(xiàn)狀價(jià)值流圖確定改善關(guān)鍵點(diǎn)繪制未來(lái)價(jià)值流圖價(jià)值流圖析循環(huán)現(xiàn)狀價(jià)值流圖價(jià)值流圖循環(huán)未來(lái)價(jià)值流圖實(shí)施計(jì)劃消除浪費(fèi)價(jià)值流圖示步驟現(xiàn)狀價(jià)值流圖價(jià)值流圖循環(huán)未來(lái)價(jià)值流圖實(shí)施計(jì)劃消除浪費(fèi)關(guān)注關(guān)鍵產(chǎn)品 … 而不是圖示所有產(chǎn)品跟蹤產(chǎn)品的整個(gè)流程（原材料 —— 加工 —— 出貨）親自在現(xiàn)場(chǎng)收集各個(gè)環(huán)節(jié)的信息并進(jìn)行手繪草圖繪圖時(shí)要充分理解整個(gè)價(jià)值流過(guò)程PQ Analysis sheet第一步：選擇價(jià)值流圖析產(chǎn)品PQ Analysis Paret Chart20:80RuleＰ１Ｐ２Ｐ３Ｐ４Ｐ５Ｐ６Ｐ７Ｐ８Ｐ９Ｐ１０Ｐ１１Ｐ１２Ｐ１３Ｐ１４Ｐ１５Ｐ１ ６Ｐ１７Ｐ１８Ｐ１９Ｐ２０0 ０１０２０３０４０５０６０７０８０９０１００累計(jì)%Ｐ ( 品種 )Ｑ數(shù)量102030405010020040080010000(10K)價(jià)值流圖標(biāo)材料流圖標(biāo)AssemblyC/T=30secC/O=40min3 shiftsScrap: 2%500 pcs1 DayI生產(chǎn)工序 外部單位 數(shù)據(jù)包 庫(kù)存出貨卡車 推動(dòng)箭頭 提供顧客合格品FIFO先進(jìn)先出順序流動(dòng)第二步：理解并應(yīng)用精益工具價(jià)值流圖標(biāo)材料流圖標(biāo)通用圖標(biāo)緩沖或備用儲(chǔ)存 超市 物理拉動(dòng)Changeover Uptime強(qiáng)調(diào)改善標(biāo)志檢查點(diǎn)信息流圖標(biāo)WeeklySchedule手動(dòng)信息流 電子信息流 計(jì)劃 負(fù)荷平衡盒去掉看板 生產(chǎn)看板 看板符號(hào) 看板位置第三步：繪制現(xiàn)狀價(jià)值流圖繪制現(xiàn)狀價(jià)值流圖　　指派繪圖員 繪制當(dāng)前價(jià)值流　　 確定客戶需求　　 確定主要工序 （按順序）　物料流 . (是拉動(dòng)還是推動(dòng) ?)　　 在每個(gè)主要工序的 數(shù)據(jù)箱內(nèi)填充數(shù)據(jù)　　確定每工序的庫(kù)存情況　　信息流示例：現(xiàn)場(chǎng)布局圖Stamping Dept.Steel Coils Stamped PartsStoragePress 1Press 4Press 3Press 2Drill 1Drill 3 Drill 4Drill 2 Grind 1Grind 2Assy 2Assy 3WIPStorageInspectShippingAssy1Machining Dept.WIP Finished Goods40,000 pcs/mo.30,000 “L”10,000 “R”Container= 50 pcs2 shiftsCustomerSupplier250 ft coils繪制圖標(biāo) ProductionControlMondaysMRP System 2 xdaily40,000 pcs/mo.30,000 “L”10,000 “R”Container= 50 pcs2 shiftsGrindAssembleDrillStamping300 T press3 shiftsEPE = 2 daysCustomerSupplier250 ft coils2 machinesC/T=36sec 19” 20” 19”10’ 8’ 8’10 20 30OPC/TC/0繪制工序流程MondaysShipStaging 2 xdaily ProductionControlMRP System40,000 pcs/mo.30,000 “L”10,000 “R”Container= 50 pcs2 shiftsGrindAssembleDrillStamping300 T press3 shiftsEPE = 2 daysCustomerSupplierTakt = secC/T= 3 sec.. = 70%FTQ = 98% C/O = 4 hrs, 1X/wk Scrap = 2%Rework = none operators = 1/shift. = 3 secShared:part 123,ABC250 ft coilsTakt = secC/T= 18 sec.. = 85%FTQ = %C/O = 40 min,1X/wk Tool C/O= 30’/day Scrap = %Rework = none operators = 1/shift. = 36 secDedicated: L,RTakt = secC/T= 20 sec.. = 75%FTQ = 98%C/O = 60 min, 1X/wk ToolC/O = 2hrs, 1X/wkScrap = 2%Rework = none operators = 1/shift. = 20 secDedicated: L,RTakt = secC/T= 20 sec.. = 90%FTQ = 95% C/O =16min,1X/day Scrap = noneRework = 5% operators = 2/shift. = 58 secDedicated: L,RGeneral Information 20 days/month hours avail./shift 2 shifts/day2 machinesC/T=36sec 19” 20” 19”10’ 8’ 8’10 20 30OPC/TC/0繪制數(shù)據(jù)箱MondaysShipStaging 2 xdaily ProductionControlMRP System40,000 pcs/mo.30,000 “L”10,000 “R”Container= 50 pcs2 shiftsShipStagingGrindAssembleDrillStamping300 T press3 shiftsEPE = 2 daysCustomerSupplierTakt = secC/T= 3 sec.. = 70%FTQ = 98% C/O = 4 hrs, 1X/wk Scrap = 2%Rework = none operators = 1/shift. = 3 secShared:part 123,ABC250 ft coilsTakt = secC/T= 18 sec.. = 85%FTQ = %C/O = 40 min,1X/wk Tool C/O= 30’/day Scrap = %Rework = none operators = 1/shift. = 36 secDedicated: L,RTakt = secC/T= 20 sec.. = 75%FTQ = 98%C/O = 60 min, 1X/wk ToolC/O = 2hrs, 1X/wkScrap = 2%Rework = none operators = 1/shift. = 20 secDedicated: L,RTakt = secC/T= 21 sec.. = 90%FTQ = 95% C/O =16min,1X/day Scrap = noneRework = 5% operators = 2/shift. = 58 secDedicated: L,RGeneral Information 20 days/month hours avail./shift 2 shifts/day2 machinesC/T=36sec 19” 20” 19”10’ 8’ 8’10 20 30OPC/TC/012023 L 4000 RI4500 L1500 RI3000 L1000 RI4500 L1500 RI500/Gon 250/Cart 100/Cart50/Cont.I4 coilsMondays500 ft coils