VSM價值流分析PPT學習教案

1、會計學1VSM價值流分析價值流分析VALUE STREAM MANAGEMENT 價值流管理價值流管理“Seeing the Whole Process Order to Cash”FOUNDATION ELEMENTS 基本改善基本改善5S+2, Employee Engagement, Problem Solving, Project Management7S, 全員參與全員參與, 問題解決問題解決, 項目管理項目管理LEAN MANUFACTURING 精益制造精益制造“Fast, Waste-Free Manufacturing Cycle Time” 快速反應(yīng)快速反應(yīng),零浪費零浪費,

2、縮短制造周期縮短制造周期DEMANDMANAGEMENT需求管理需求管理“Consistent Flow of Orders”SUPPLY CHAINEXECUTION供應(yīng)鏈管理供應(yīng)鏈管理“Reliable Flow of Materials”SIX SIGMA“Eliminating / Managing Variation in Manufacturing and Business Processes”消除消除 / 管理在制造過程中的誤差管理在制造過程中的誤差LEAN BUSINESS PROCESSES精益商業(yè)過程精益商業(yè)過程“Fast, Error-free Transaction F

3、low”快速反應(yīng)快速反應(yīng), 零誤差交易流零誤差交易流第1頁/共64頁OperationsStrategicPlanning操作的策略性規(guī)劃ExecutiveEducation管理層培訓OrganizationalEducation內(nèi)部組織培訓Planning andPreparation規(guī)劃與準備規(guī)劃與準備Value-StreamMapping價值流圖價值流圖Project Management and Execution 項目管理與執(zhí)行項目管理與執(zhí)行Target Design設(shè)計目標流程設(shè)計目標流程Current StateCurrent State當前狀態(tài)當前狀態(tài)Future State(

4、未來狀態(tài)未來狀態(tài))Action Plan行動計劃行動計劃拉式進度安排；看板ContinualImprovement持續(xù)改進持續(xù)改進平衡生產(chǎn)線設(shè)計、培訓精益商業(yè)流程設(shè)計培訓重點培訓重點數(shù)據(jù)采集 -基準度量標準 -產(chǎn)品/工藝 -批量/混線生產(chǎn) -流程圖 -工作內(nèi)容其他工具和培訓（如有需要）-品質(zhì)改進 -預防性維護-減少作業(yè)準備 -改善-差錯預防 -6&工具 Foundations（基礎(chǔ)）（基礎(chǔ)）: Employee Involvement Culture（全民參與的文化） 7S - Workplace Organization（7s-整理工作場所） Structured Problem S

5、olving（系統(tǒng)化的解決問題方案）第2頁/共64頁第3頁/共64頁第4頁/共64頁第5頁/共64頁第6頁/共64頁第7頁/共64頁第8頁/共64頁第9頁/共64頁七大模塊七大模塊VSM 8步曲步曲細節(jié)細節(jié)/備注備注模塊1: 啟動第1步: Lean的承諾第2步: 選擇價值流價值流管理的介紹模塊2: Lean的基礎(chǔ)第3步: 學習LeanLean的基礎(chǔ)模塊3: 識別當前狀態(tài)第4步: 當前價值流圖繪制; 第5步: 識別 Lean指標當前狀態(tài)模塊4: 未來狀態(tài)的繪制; 客戶需求階段第6步: 未來價值流圖的繪制; 客戶需求階段客戶需求模塊5: 未來狀態(tài)的繪制; 連續(xù)流動階段第6步: 未來價值流圖的繪制;

6、 連續(xù)流動階段連續(xù)流動模塊6: 未來狀態(tài)的繪制; 平衡(適物/時/量)階段第6步: 未來價值流圖的繪制; 平衡(適物/時/量)階段平衡(適物/時/量)模塊7: Kaizen改善計劃第7步: 定義Kaizen改善計劃第8 步: 執(zhí)行Kaizen改善計劃你的未來Lean歷程!第10頁/共64頁第11頁/共64頁第12頁/共64頁(P-Q)產(chǎn)品產(chǎn)品-數(shù)量分析圖數(shù)量分析圖0200050010001500P1P3P5P7P9P11P13P15P17P19P21P23P25P27P29P3120%40%60%80%100%A組組(70%)B組組(70-95%)C組組(95-99%)產(chǎn)品產(chǎn)品P4：6比率線比

7、率線120%3：7比率線比率線2：8比率線比率線第13頁/共64頁加工過程分析表加工過程分析表*從不同產(chǎn)品中指出類似的流程從不同產(chǎn)品中指出類似的流程(指數(shù)指數(shù)(或索引或索引)可以是工序名可以是工序名/時間間隔時間間隔/工序間距離工序間距離)*找出能共用一組設(shè)備，同一個生產(chǎn)單元生產(chǎn)的產(chǎn)品族。找出能共用一組設(shè)備，同一個生產(chǎn)單元生產(chǎn)的產(chǎn)品族。第14頁/共64頁第15頁/共64頁第16頁/共64頁第17頁/共64頁第18頁/共64頁第19頁/共64頁第20頁/共64頁第21頁/共64頁第22頁/共64頁第23頁/共64頁第24頁/共64頁STORY BOARD第25頁/共64頁第26頁/共64頁第27

8、頁/共64頁Value Stream Mapping(Flow Kaizen)價值流程圖價值流程圖（流動式改善）（流動式改善）VSM第28頁/共64頁第29頁/共64頁第30頁/共64頁Select VSM Manager確定價值流經(jīng)理確定價值流經(jīng)理Select Product Family確定產(chǎn)品族確定產(chǎn)品族Current State Map當前狀態(tài)圖當前狀態(tài)圖Future State Map未來狀態(tài)圖未來狀態(tài)圖Prioritized Implementation Plan 有優(yōu)先次序的實施計劃有優(yōu)先次序的實施計劃第31頁/共64頁第32頁/共64頁Select VSM Manager確定價

9、值流圖經(jīng)理確定價值流圖經(jīng)理Select Product Family確定產(chǎn)品族確定產(chǎn)品族Current State Map當前狀態(tài)圖當前狀態(tài)圖Future State Map未來狀態(tài)圖未來狀態(tài)圖Prioritized Prioritized Implementation PlanImplementation Plan 有優(yōu)先次序的實施計劃有優(yōu)先次序的實施計劃 第33頁/共64頁第34頁/共64頁Select VSM Manager確定價值流圖經(jīng)理確定價值流圖經(jīng)理Select Product Family確定產(chǎn)品族確定產(chǎn)品族Current State Map當前狀態(tài)圖當前狀態(tài)圖Future St

10、ate Map未來狀態(tài)圖未來狀態(tài)圖PrioritizedImplementation Plan有優(yōu)先次序的實施計劃有優(yōu)先次序的實施計劃第35頁/共64頁第36頁/共64頁第37頁/共64頁第38頁/共64頁40Mapping Icons 描繪圖標描繪圖標Material Flow IconsInternal Processes WeeklyTruck ShipmentC/T = 45 secC/O = 30 mins3 Shifts2% ScrapData Boxmax 20 piecesFIFOFirst-In-First-OutSequence FlowSupermarketWithdra

11、walGeneral IconsBuffer orSafety StockInformation Flow IconsManualInformation FlowProductionKanbanKanban Arrivingin BatchesWeeklyScheduleInformationOXOXLoad-LevelingSignal KanbanKanban PostSequenced-PullBall“Go-See”SchedulingOutside SourcesXYZCorporationOperatorMaterial Flow to/fromOutside SourcesWIP

12、WasteComputer WIPOperationPush Arrow ElectronicInformation FlowWithdrawalKanbanHeijunka BoxABC1 Pc FlowUptimeImprovement Burst第39頁/共64頁第40頁/共64頁第41頁/共64頁 Total Work Content / Takt time (realistic 85% factor) 總的產(chǎn)量總的產(chǎn)量/ / 節(jié)拍時間節(jié)拍時間1. Average Method 求平均值法求平均值法: 23 min x 60 sec. / 200 seconds x 1.15 = 7.

13、95 people = 8 Assume Work Content is 23 minutes 假定工作量需要假定工作量需要23分鐘分鐘2. Peak Line Rate 高峰速率生產(chǎn)高峰速率生產(chǎn): 23 min x 60 sec. / 178 seconds x 1.15 = 8.91 people = 93. Low season 淡季淡季: 24 min x 60 sec. / 258 seconds x 1.15 = 6.13 people = 6 (ot)Try to design a line that can be staffed “efficiently” by either

14、6 or9 people and shifting work content（通過（通過6 6或或9 9人變換工作容量設(shè)法設(shè)計一條能夠人變換工作容量設(shè)法設(shè)計一條能夠有效地配置人員的生產(chǎn)線）有效地配置人員的生產(chǎn)線）第42頁/共64頁TaktTaktTaktFloat第43頁/共64頁OSA SUMMARY121110987654321CUT FLANGEHOLE P UNCHFORMHEAT TREATCLEANVALVE BODY ASS YWELDS TAMPC/M ASS YFINAL AS SYINSPPACKSET-UP TIMELOT S IZETAKTLINE RATE:_ TAK

15、T: _What can be eliminated? What can be combined? What can be simplified?WORKCONTENT(SEC. PC)第44頁/共64頁Shipping 海運海運Customers( (消費者消費者) )Product Line - ABC Motors產(chǎn)品族產(chǎn)品族ABCABC族族Line rate 258 day生產(chǎn)線速率生產(chǎn)線速率每天每天258件件Takt Time 200 seconds節(jié)拍時間節(jié)拍時間200秒秒DEF 1200 mo./月月DFG 900 mo./月月ADT 800 mo./月月XYZ 600 mo./

16、月月CBC 500 mo./月月每周二次每周二次Begin with the Customer從顧客開始從顧客開始卡車運貨卡車運貨第45頁/共64頁Shipping貨運貨運Test測試測試AssemblyAssembly 總裝總裝Customer顧客顧客Product Line ABC產(chǎn)品族產(chǎn)品族ABC族族Line rate 258 day生產(chǎn)線速率生產(chǎn)線速率258天天Takt Time 200 sec.節(jié)拍時間節(jié)拍時間200秒秒Hsg.Hsg.MachMach外殼加工外殼加工Shaft Mach主軸加工主軸加工Add the upstream processes展示上游工藝流程展示上游工藝流

17、程第46頁/共64頁第47頁/共64頁Uptime=86%SUBASSY/TESTC/T=7.5 mins32 shiftsRange = 5-10300 sku C/O= 5 min.“4 up” test420 min. availMTBF = 0.5 daysMTTR = 30 min.FPY = 93% - Avg Cycle Time(平均操作時間平均操作時間) ) - Mix Range (ABC, Q analysis called for)()(產(chǎn)品類型范圍產(chǎn)品類型范圍(ABC(ABC數(shù)量分析數(shù)量分析) - Production “batch size”(生產(chǎn)批量生產(chǎn)批量) -

18、 Product variety(產(chǎn)品種類產(chǎn)品種類) - Set-Up time(作業(yè)準備時間作業(yè)準備時間) - Avg Uptime(機器平均正常使用時間機器平均正常使用時間) - Downtime Stats(平均故障間隔時間平均故障間隔時間) - Mean time to repair(平均修復時間平均修復時間) - First Pass Yield( (一次性合格率一次性合格率) - Working Time per day(每天生產(chǎn)時間每天生產(chǎn)時間)No. of Operators(工人數(shù)目工人數(shù)目)No. of shifts( (每天班次每天班次) )Note: The Data

19、Box is customized to the specific operations and contains only the data that is pertinent 數(shù)據(jù)盒數(shù)據(jù)盒根據(jù)各生產(chǎn)崗位的特性而只包括相關(guān)的根據(jù)各生產(chǎn)崗位的特性而只包括相關(guān)的適用數(shù)據(jù)。適用數(shù)據(jù)。 - I/D the process( (工藝過程工藝過程) )Other data as required- No of machines(設(shè)備數(shù)量設(shè)備數(shù)量)- Daily req. if shared(每天需求量每天需求量, ,當共享當共享 設(shè)備時設(shè)備時)- Where does the process get i

20、nfo on what to run(本流程本流程/ /程序如何取得生產(chǎn)程序如何取得生產(chǎn) 指令指令) - Average output / shift 平均每班產(chǎn)量平均每班產(chǎn)量Count WIP(work-in-process) between operations第48頁/共64頁Data Collection Sheet 數(shù)據(jù)收集表數(shù)據(jù)收集表Operation Name _Set-Up Time _ per _ PcsTimeTimeTimeTimeTimeTimeTimeElement#Operation SequenceNetNetNetNetNetNetNetTimeTQCCycle

21、= OPERATION CYCLE TIMEUnderstanding Work 了解工作了解工作第49頁/共64頁Set-Up TimeOperation Name1Pick up part; load fixture2 Gage clearance3Select shim4 Install shim; rotate5Place gasket and cover6 Drive four bolts7Check fit; flip; load test8Unload; Move Start Tester; Test910 Wait for Next part12Cover and Test10

22、 min.20026521.371.592.503.044.104.254.50121426452251146615251413151576*25* Had to leave area to get load of Shims (once a day)40382022605812156867201830355.045.196.357.157.358.358.479.5510.1510.4510.5811.1311.3812.1612.3813.3613.5114.5815.1615.514.505.555.06Check for spur gear131526422258146718305.0

23、5perPcsTimeTimeTimeTimeTimeTimeTimeElement#Operation SequenceNetNetNetNetNetNetNetTimeTQCCycle= OPERATION CYCLE TIME131626422157146617311416274323591569203116.0416.2016.4617.2817.4918.4619.0020.0620.2320.5421.0821.2421.5122.3422.5723.5624.1125.2025.4026.115.035.07Data Collection Sheet 數(shù)據(jù)收集數(shù)據(jù)收集表表EXAM

24、PLE 樣板樣板第50頁/共64頁OPERATORMACHINEWALK / RIDEIDLE / WAITTQCNVAOPERATIONAL TIME#Operation / Sequence( x )OPERMACHMOVETOTAL TIME Set-Up TimeSET-UP ANALYSIS Lot SizeTIME ESTIMATELINE RATETAKT TIMEOPERATORMACHINEOPERATIONS SEQUENCE ANALYSIS (OSA)第51頁/共64頁OPERATIONS SEQUENCE ANALYSIS (OSA)LINE RATEOPERATOR

25、MACHINETAKT TIMEWALK / RIDEIDLE / WAITTQCNVATIME ESTIMATEOPERATIONAL TIME#Operation / Sequence( x )OPERMACHMOVE TOTAL TIME SetUp TimeOPERATORSET-UP ANALYSIS Lot SizeMACHINE1Pick up part; load fixture2Gage clearance3Select shim4Install shim; rotate5Place gasket and cover6Drive four bolts7Check fit; f

26、lip; load test8Unload; Move Start Tester; Test910Wait for Next partx13152642225814671830 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320105 units per shift240 sec.TAKT加工順序分析表加工順序分析表第52頁/共64頁OPERATIONS SEQUENCE ANALYSIS (OSA)LINE RATEOPERATORMACHINETAKT TIMEWALK / RIDEIDLE / WAITTQCNVATIM

27、E ESTIMATEOPERATIONAL TIME#Operation / Sequence( x )OPERMACHMOVE TOTAL TIME SetUp TimeOPERATORSET-UP ANALYSIS Lot SizeMACHINE7Install shim; rotate8Place gasket and cover9Drive four bolts422258 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320105 units per shift240 sec.TAKT1Check fit; flip;

28、 load test2Unload; move part #1Start tester; test part #161467183Pick up part #2; load fixturex134Gage clearance155Select shim261011Set down shimPick up shim44改進加工順序改進加工順序第53頁/共64頁Shipping 貨運貨運Test測試測試AssemblyAssembly 總裝總裝Customer 顧客顧客Product Line ABCLine rate 258 dayTakt Time 200 sec.Hsg.Mach外殼加工外殼

29、加工Shaft Mach 主軸加工主軸加工Add the upstream processes展示上游工藝流程展示上游工藝流程See details next page 細節(jié)如下圖細節(jié)如下圖卡車運貨卡車運貨第54頁/共64頁Assem 總裝總裝Customer 顧客顧客FinGrind磨磨光光Turn Cell轉(zhuǎn)轉(zhuǎn) 單元單元Mill Key車栓位車栓位387015 dayM-1,1,02 shiftsC/T 1 mins/u 20 minrel - 80%scrap 20% ?25,000 sec availOutput 155 shiftbatch 50015506 day7753 dayM

30、-1,1,13 shiftsC/T 3 mins/u 10 minrel 95%scrap 1%25200 sec availoutput 100 shiftbatch5001420shared130.5 dayHeat treat熱處理熱處理M-1,1,13 shift4.5 hrs60 sec / pcs/u-30minM-1,1,02 shiftsc/t 2 mins/u 10 minrel-98%scrap 8%output150 shiftetcShaft Machining 主軸加工主軸加工?Product Line(產(chǎn)品族產(chǎn)品族) ABCLine rate(生產(chǎn)線速率生產(chǎn)線速率)

31、 258 dayTakt Time(節(jié)拍時間節(jié)拍時間) 200 sec.第55頁/共64頁 Shipping 貨運貨運外殼外殼加工加工主軸主軸加工加工Test 測試 Assembly 總裝總裝CustomerAdd the supplier info 加入供應(yīng)商信息加入供應(yīng)商信息 - not all but a few key 只顯示主要的只顯示主要的 - frequency of delivery 交貨頻率交貨頻率 - batch size 批量批量 - days of supply每次交貨可用多少天每次交貨可用多少天Outside Sources WeeklyTruck Shipment

32、卡車運貨卡車運貨卡車運貨卡車運貨第56頁/共64頁 Shipping 貨運貨運Test測測試試 Assembly 總裝總裝Customer 客戶客戶ProductionControl 生產(chǎn)控制生產(chǎn)控制ForecastForecastWeekly Orders周訂單周訂單Monthly Orders月訂單月訂單MRPShaftShaftMachMach主軸加工主軸加工Hsg.Mach外殼加工外殼加工Weekly SchedulesDaily Sched每天計劃每天計劃Supplier 供應(yīng)商供應(yīng)商卡車運貨卡車運貨第57頁/共64頁Assem 總裝總裝Customer 顧客顧客Product Li

33、ne(產(chǎn)品族產(chǎn)品族) ABCLine rate(生產(chǎn)線速率生產(chǎn)線速率) 258 dayTakt Time(節(jié)拍時間節(jié)拍時間) 200 sec.FinGrind磨光磨光Turn Cell轉(zhuǎn)單元轉(zhuǎn)單元Mill Key車栓位車栓位387015 dayM-1,1,02 shiftsC/T 1 mins/u 20 minrel - 80%scrap 20% ?25,000 sec availOutput 155 shiftbatch 50015506 day7753 dayM-1,1,13 shiftsC/T 3 mins/u 10 minrel 95%scrap 1%25200 sec availou

34、tput 100 shiftbatch50014205.5 dayShared共享共享130.5 dayHeatTreat熱處理熱處理M-1,1,13 shift4.5 hrs60 sec / pcs/u-30minM-1,1,02 shiftsc/t 2 mins/u 10 minrel-98%Scrap(廢品廢品) 8%output150 shiftEtc(產(chǎn)量產(chǎn)量150/150/班班)Shaft Machining主軸加工主軸加工 第58頁/共64頁Total Lead Time = Sum of supplier & production lead time 總周期時間總周期時

35、間= =供應(yīng)商及生產(chǎn)的總周期時間供應(yīng)商及生產(chǎn)的總周期時間Value Added Ratio(VAR) = Total work content time* / Throughput time 增值率增值率= =總的工作量總的工作量( (時間時間)/)/生產(chǎn)周期生產(chǎn)周期Throughput = Internal process lead time or production lead time above 生產(chǎn)周期生產(chǎn)周期= =上述的內(nèi)部流程周期時間或生產(chǎn)周期時間上述的內(nèi)部流程周期時間或生產(chǎn)周期時間7 min(分分)4 min(分鐘分鐘)2 min(分鐘分鐘)15 days( (天天)7 days(天天)15 days15(天天)Production Lead Time 生產(chǎn)周期生產(chǎn)周期Lead Time Data Bar 時間線時間線Work Content*Time 工作量工作量( (時間時間) ) WC