當(dāng)前價(jià)值流圖計(jì)算.doc

P Updated definition of Value Stream 價(jià)值流定義While value streams may be defined broadly at the product level (e.g., large engines), or narrowly at the process level (e.g., canopy tack weld), manufacturing sections are the basic building blocks of the value streams. CPS requires the alignment of value stream definitions with manufacturing section definitions. Individual business units establish the section structure for quality management and certification, and financial management. Section managers, formerly referred to as frontline supervisors, combine responsibilities for managing teams of production employees, and value stream, quality and financial management.價(jià)值流包含廣義上的產(chǎn)品級(jí)別 (比如大發(fā)動(dòng)機(jī)) 或者狹義上的流程級(jí)別 (比如頂蓋點(diǎn)焊接), 生產(chǎn)的各個(gè)區(qū)域/車(chē)間是基本的價(jià)值流元素。 卡特彼勒生產(chǎn)系統(tǒng)結(jié)合了價(jià)值流定義與生產(chǎn)區(qū)域的定義。各個(gè)業(yè)務(wù)單元為管理質(zhì)量、認(rèn)證和財(cái)務(wù)管理建立了自己相應(yīng)的區(qū)域結(jié)構(gòu)。車(chē)間經(jīng)理，以前叫做一線(xiàn)主管，既要管理生產(chǎn)團(tuán)隊(duì)，也要管理價(jià)值流，質(zhì)量和財(cái)務(wù)。Value Stream Mapping 價(jià)值流圖Cycle Time 周期時(shí)間Cycle time is defined as a timed observation of how often a part or product is completed by a process. In other words, cycle time is the process exit rate.周期時(shí)間定義是經(jīng)過(guò)一個(gè)流程某一零件或產(chǎn)品完成的時(shí)間。換言之，周期時(shí)間是流程產(chǎn)出率。When practical, multiple observations should be made. The lowest repeatable time should be used as observed cycle time. The operator should always be involved in determining cycle time. The observed cycle time is a measure of both value-added and non-value-added time in the process.觀(guān)察周期時(shí)間是，應(yīng)當(dāng)按實(shí)際的、多次的觀(guān)測(cè)取值。最短的重復(fù)時(shí)間通常被用做觀(guān)測(cè)的周期時(shí)間值。操作者應(yīng)當(dāng)參與周期時(shí)間的測(cè)算。所觀(guān)察的周期時(shí)間是一個(gè)流程內(nèi)增殖和非增殖時(shí)間的總和。Measuring cycle time needs to be kept in appropriate context. If a batch of parts undergoes the same process step, then the observed cycle time applies to the full batch. The cycle time per piece is computed as observed cycle time divided by number of pieces in a batch.我們需要在某一特?cái)M定的環(huán)境下測(cè)量計(jì)算周期時(shí)間。 如果一批次零件經(jīng)過(guò)同一個(gè)流程步驟，那么觀(guān)測(cè)到的周期時(shí)間為整個(gè)批次的周期時(shí)間。單件的周期時(shí)間則是總的周期時(shí)間除以這一批次零件數(shù)量。Cycle Time Piece = Cycle Time / Batch Size 單件的周期時(shí)間=周期時(shí)間/批量規(guī)模If multiple part numbers with comparable observed cycle times go through the same process step, calculate the weighted average (based on demand) cycle time and record it in the process box.如果多個(gè)件號(hào)零件也同樣經(jīng)過(guò)同一流程步驟，應(yīng)當(dāng)計(jì)加權(quán)平均周期時(shí)間（基于需求）并記錄在流程圖的周期時(shí)間框位置。Note: Record cycle time and batch size in the process box for each process step.備注：每一道工序都應(yīng)在工序的周期時(shí)間框中記錄周期時(shí)間和批量規(guī)模。Process Time 流程時(shí)間Process time is the time it takes for all the work elements to be completed. Process time includes both value-added and non-value-added steps. The concept of process time is closely related to cycle time. In many situations cycle time and process time are equivalent. Heat treat and paint process are typical examples when process time (floor-to-floor including load and unload) is longer than observed cycle time.流程時(shí)間是完成所有工作要素所需要的時(shí)間。流程時(shí)間包括增殖和非增殖的所有步驟。流程時(shí)間的概念和周期時(shí)間密切相關(guān)。在很多情況下兩者是同一個(gè)數(shù)值。熱處理和噴漆流程是非常典型的流程時(shí)間（從裝載到卸載）明顯比周期時(shí)間長(zhǎng)的例子。Example 示例:Heat treat process takes 180 min. Every six minutes a batch of six parts exits the heat treat furnace. 熱處理流程時(shí)間是180分鐘。 加熱爐每六分鐘就完成一批產(chǎn)品，每批產(chǎn)品6件。Batch size = 6 pieces 批量大小=6件Cycle Time = 6 min 周期時(shí)間=6分Cycle Time Piece = 6 min / 6 pieces = 1 min 單件的周期時(shí)間=6分/6件=1分Process Time = 180 min 流程時(shí)間=180分Process time is how long the part is being worked on within the process; floor-to-floor time, including load and unload; one complete sequence of work elements. 流程時(shí)間是零件在某一流程內(nèi)被處理的時(shí)間；時(shí)間間斷，包括裝夾和卸載的時(shí)間；是一個(gè)完整的工作要素序列。Total Product Cycle Time 產(chǎn)品總周期時(shí)間To represent the time component of the value stream, compute the total product cycle time or TCTP, which is an estimate of the time required for the product to move through a value stream at current demand levels. TCTP is a measure of the ability to meet customer demand. 產(chǎn)品總周期時(shí)間包含價(jià)值流所有時(shí)間元素，它是在當(dāng)前需求水平下產(chǎn)品經(jīng)過(guò)一個(gè)價(jià)值流所需要的時(shí)間。TCTp它用來(lái)衡量滿(mǎn)足客戶(hù)需求的能力。FormulaThe formula used to calculate total product cycle time is:TCTP = WIP / Current Customer Demand Rate公式用于計(jì)算產(chǎn)品總周期時(shí)間的公式是:TCTP = 在制品 / 當(dāng)前客戶(hù)需求率Total Demonstrated Cycle Time 實(shí)際總周期時(shí)間Total demonstrated cycle time or TCTD is a measure of the current ability of the value stream to produce. The calculation of TCTD is based on current levels of inventory and the demonstrated production rate (meaning the average exit rate of products to the customer).實(shí)際總周期時(shí)間用來(lái)衡量?jī)r(jià)值流當(dāng)前的生產(chǎn)的能力。其計(jì)算TCTd要基于當(dāng)前庫(kù)存水平和當(dāng)前實(shí)際生產(chǎn)率 （意指交付給客戶(hù)的平均產(chǎn)品產(chǎn)出率）FormulaThe formula used to calculate total demonstrated cycle time is:TCTD = WIP / Demonstrated Exit Rate公式用于計(jì)算實(shí)際總周期時(shí)間公式是:TCTD =在制品/ 實(shí)際產(chǎn)品產(chǎn)出率Comparing TCTP to TCTD determines the gap in the current ability to meet a customer demand. Both TCTP and TCTD are recorded on the value stream map. 對(duì)比產(chǎn)品總周期時(shí)間和實(shí)際總周期時(shí)間從而展示出當(dāng)前滿(mǎn)足客戶(hù)需求的能力的差距，兩者都被記錄在價(jià)值流圖里。Cycle Efficiency 周期效率Process time and TCTP calculations are used to compute cycle efficiency, which is a ratio of the sum of process time to Total Product Cycle Time (TCTP)流程時(shí)間和產(chǎn)品總周期時(shí)間的結(jié)果用來(lái)計(jì)算周期效率，它是流程時(shí)間的總和與產(chǎn)品總周期時(shí)間的比值。FormulaThe formula used to calculate cycle efficiency is:Cycle efficiency = Sprocess time / TCTP公式用于計(jì)算周期效率的公式是:周期效率= S流程時(shí)間/ 產(chǎn)品總周期時(shí)間TCTPEffective Cycle Time 有效的周期時(shí)間To show the effect of wastes over time, CPS recommends calculating and analyzing effective cycle time. The OEE metric captures the percentage of wastes related to equipment downtime losses, performance losses and quality losses.為反應(yīng)出時(shí)間浪費(fèi)的影響，CPS推薦計(jì)算和分析有效周期時(shí)間。而OEE指標(biāo)用于捕獲設(shè)備停機(jī)時(shí)間損失、績(jī)效和質(zhì)量損失相關(guān)的浪費(fèi)。FormulaThe formula for calculating effective cycle time is:Cycle Time EFFECTIVE = Cycle Time piece / %OEE公式用于計(jì)算有效周期時(shí)間:有效周期時(shí)間= 單件周期時(shí)間/ %設(shè)備綜合效率OEEExample 示例: Assume observed cycle time per piece = 46 minutes.假設(shè)單件周期時(shí)間=46分鐘 Assume OEE = 67% (includes wastes due to machine breakdowns, long changeover, re-work, etc.).OEE=67% （包含由于機(jī)器停機(jī)、長(zhǎng)時(shí)間的換型和返工等產(chǎn)生的浪費(fèi)）Effective Cycle Time = 46 / 67% = 46 / 0.67 = 68.6 minutes 有效周期時(shí)間=46/0.67=68.6分鐘Include Effective Cycle Time on the TT/CT Bar Chart