勞斯萊斯精益案例課件

勞斯萊斯精益案例管道由于地形高差相差大，或支線接人埋設(shè)較深的主干線時(shí)出現(xiàn)較大的跌落水頭，需要設(shè)置跌水井，以克服水流跌落時(shí)產(chǎn)生的巨大沖擊力。采用豎槽式混凝土跌水井（蓋板式）D=200-400mm（直線外跌）。本設(shè)計(jì)中，由于地形較平坦，無(wú)較大跌落水頭，無(wú)需設(shè)置跌水井。勞斯萊斯精益案例勞斯萊斯精益案例管道由于地形高差相差大，或支線接人埋設(shè)較深的主干線時(shí)出現(xiàn)較大的跌落水頭，需要設(shè)置跌水井，以克服水流跌落時(shí)產(chǎn)生的巨大沖擊力。采用豎槽式混凝土跌水井（蓋板式）D=200-400mm（直線外跌）。本設(shè)計(jì)中，由于地形較平坦，無(wú)較大跌落水頭，無(wú)需設(shè)置跌水井。ValueSteamMappingTheValueStream-adefinition“Allofthestepsrequiredtobringaproductorservicefromrawstatethroughtothecustomer”TotalValueStreamSupplierProcessCProcessBProcessACustomerInternalPlant2勞斯萊斯精益案例管道由于地形高差相差大，或支線接人埋設(shè)較深的勞斯萊斯精益案例課件ValueSteamMappingWhatisValueStreamMapping?ValueStreamMappingisapowerfultechniquethatallowsustocreatea“BIGPICTURE”visualrepresentationof:–Allthestepsintheprocess,workingbackfromcustomerdemandtorawmaterial–Theflowofbothmaterialandinformationandtheeffecttheyhaveoneachother–Thedistinctionbetweenvalue-addedandnon-value-addedactivity(WASTE)–Theeffectalloftheabovehaveonmeetingthecustomer’srequirements3ValueSteamMappingWhatisValValueSteamMappingThe8WastesScrap/ReworkOver-productionInventoryMotionProcessingTransportationUnder-utilizedPeopleWaiting(manpower,material,machine)4ValueSteamMappingThe8WasteValueSteamMapping#1Scrap/ReworkDefinition:–AnyproductthatdoesnotmeetspecificationsandthereforeeitherneedstobereworkedorscrappedGoal:–100%FirstTimeThroughQuality5ValueSteamMapping#1Scrap/ReValueSteamMapping#2Over-production(Under)Definition:–Producingmorethanisnecessary,oftencausingWIP(WorkInProcess);workingonpartsaheadofschedulewhiledelinquentpartswaitGoal:–ProducetoTargetCycleTimetheneventuallyproducealloperationstoTaktTimeintheFutureState6ValueSteamMapping#2Over-proValueSteamMapping#3InventoryDefinition:materialorpartsthatarestoredforfutureuseorshipmentBeforeAfterIfyouhadonly30secondstofindtheunit…...whichstoragesystemwouldyouchoose?7ValueSteamMapping#3InventoValueSteamMapping#4MotionDefinition:–ExcessivemotionbeyondwhatisneededtogetthejobdoneGoal:SameasDefinition???sittingsearchingturningaroundwalkingclimbingchoosingbendinglyingdownover8ValueSteamMapping#4MotionDeValueSteamMapping#5Processing(Over&Under)Definition:–Extraand/orunnecessaryoperations–Standardizationofoperationsnotthoroughenough–ProcessingapartabovespecificationsGoal:–Processpartsthatconsistentlymeettheminimumcustomerrequirements100%ofthetime9ValueSteamMapping#5ProcessiValueSteamMapping#6TransportationDefinition:–MovingpartstounnecessarydistancesfromoneoperationtoanotherGoal:–Putoperationsinorder;minimizeoreliminatethetraveldistancebetweenthem10ValueSteamMapping#6TransporValueSteamMapping#7WaitingDefinition:–apersonorpart(s)sittingidlewhilewaitingformaterial,asupervisor,thenextoperation,etc.Goal:–Eliminatetheunplannedinterruptionsthatoccurduetoinefficiencies–Developcontinuousflowwhereverpossible–Convertwaitingtovalue-addedwork11ValueSteamMapping#7WaitingDValueSteamMapping#8Under-utilizedPeopleDefinition:–Skillsuntapped,IdeasnotimplementedandimprovementsnotrealizedGoal:–Tapintotheenergiesandunusedimprovementideasfromtheworkforce12ValueSteamMapping#8Under-utValueSteamMappingExerciseWorksheetMANUFACTURINGWASTESIDENTIFICATIONSHEETDept:_______________TransportationUnder-utilizedPeopleScrap/ReworkOver(Under)ProductionProcessing5S-Sort,Straighten,Sweep,Standardize&SelfDisciplineInventoryNO.WASTEIDENTIFIEDJohnMcLauchlinRevisionDate:4/25/2000WaitingMotion13ValueSteamMappingExerciseWoValueSteamMappingValueStreamAnalysisProcessValueStreamMapping1.0SelectChampionandInitialProductFamily2.0Gather,Map,andAnalyzeSelectedValueStreamData3.0DesignFutureState4.0ImplementationPlanningandExecution1.Understandbusinessgoalsandcustomerobjectives2.Selectchampionandvaluestreamleadersbasedonprovencriteriaforsuccess3.Defineproductfamiliesbasedoncommonprocessesandequipment14ValueSteamMappingValueStreaValueSteamMappingLeadershipandChampionsObservationsLeanAerospaceInitiative–AcommonfactorinallobservedsuccessfulleanimplementationsisoneormoreempoweredChampions.–Championsareusuallyhigh-levelleaderswhotakeonapro-activeroleshapingandsupportingtheleaninitiatives,andensuringthatsystembarriersareidentifiedandaddressed.–Tostartyourleanjourney,youneedaleaderorsetofleadersto:?Developastrategicdirection?Agreetoandcommunicatethestrategicdirection?Makeavailabletheneededresources?Providecontinued,visiblesupport–Withoutthesupportofachampion,youshouldnotattempttoimplementleanpracticesandprinciples--itisarecipefordisaster15ValueSteamMappingLeadershipValueSteamMappingSmallGroupActivity?Identifywhoinyourorganizationwillfillthesecriticalrolestosupportleanimplementation–ExecutiveChampion–ImplementationLeader–OperationsManager–TechnicalSupport–OtherKeyRoles??Brieflydescribetheroleeachpersonwillhaveinsupportinglean?Whatcanyoudotogetthesepeopletosuccessfullysupportyourefforts?ExecutiveChampion?ImplementationLeader?OperationalMgr16ValueSteamMappingSmallGroupValueSteamMappingDefineProductFamilies?AnalyzeProduct-VolumeCharttoseparatehighrunnersfromlowrunners?AnalyzeProduct-ProcessMatrixtoidentifysimilarprocessingstepsandcommonequipment?AnalyzeRoutingstoidentifycommonsequencesfocusingon:–Operationsthatcanpotentiallybededicatedtotheproductfamily–Operationsthatareneithermonumentsnorbatchcycles–Downstreamprocessesmostvisibletothecustomer17ValueSteamMappingDefineProdValueSteamMappingAnalyzeProduct-VolumeCharttoseparatehighrunnersfromlowrunnersProductVolumeChart450040003500AnnualVolume3000250020001500100050002206215021702158210821422124210221722212222222022204PartNumber18ValueSteamMappingAnalyzeProValueSteamMappingAnalyzeProduct-processMatrixtoIdentifySimilarProcessingStepsandCommonEquipmentVol.400360450450760620750322583002684000PNs2124210221082142215021582170217222042212222222064070RoughH.T.TurnDeburrInspBlackMPIShipMarkMillSawDrillCopprGrindWeldPlasmaXXXXXXXXXXXXXXXXXXXX8338XXXXXXXXXXX8338XXXXXXXXXXX8338XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX39783138180052000XXXXXXXX82803712XXXXXXX4326X4000584280833819ValueSteamMappingAnalyzeProValueSteamMappingAnalyzeRoutingstoIdentifyCommonSequencesTypesofMachinesRough1234456InspBlackMPIGrindWeldCopprPlasma78910111214ASSMFPICoatLapPolishPaintNickel15161718192021BatchorOutSourcedNon-monumentH.T.TurnMillDrillDeburrMarkProductFamily“A”21242102210821422150215821722170220422122222220611111111111211111221112221211227232333333333333453333333333333444444444104455555555511556666666661588888888149911999777777333991021173777551041616319315715720715711222333333“C”“B”50%ofTotalVolume20ValueSteamMappingAnalyzeRouValueSteamMappingValueStreamAnalysisProcessValueStreamMapping1.0SelectChampionandInitialProductFamily2.0Gather,Map,andAnalyzeSelectedValueStreamData3.0DesignFutureState4.0ImplementationPlanningandExecution1.Gathercustomerinformation2.Walktheprocess-sketchprocessboxes.3.Fillinprocessdataboxesandinventorylevels(byproduct).4.Documenthowgoodsaredeliveredtothecustomer.5.Gatherinformationonsuppliers.6.Addinformationflows.7.Sketchhowmaterialmovesbetweenprocesses.8.Drawproductionleadtime/value-addedtimeline.21ValueSteamMappingValueStreaValueSteamMappingMaterialFlowIconsAssemblyXYZCorporationProcessBoxSupplier/CustomerC/T=45sec.C/O=30min.3Shifts.2%ScrapI300pieces1dayInventorySupermarketBufferorSafetyStockDataBoxMon+WedShipmentPushPhysicalPullFinishedGoodstoCustomerFIFOFirst-In-First-OutOperator22ValueSteamMappingMaterialFlValueSteamMappingInformationFlowIconsWeeklyScheduleManualInformationFlowElectronicInformationFlowScheduleOXOXLoadLevelingBoxSequenced-PullBallUptimeChangeoverWithdrawalKanbanProductionKanbanSignalKanbanKanbanPostKaizenLightningBurst23ValueSteamMappingInformationValueSteamMappingMappingTips??????????Useapencilanddrawon11”x17”paperorlargerDrawtopofprocessboxesjustbelowthemiddleofthepageLeaveenoughroombetweenprocessboxestoshowinventoryDecidewhethertocountallpartsorjustasamplepartDrawonlyonetothreemainsuppliers/supplieditemsProductionleadtimeiscalculatedbydividinginventoryquantitybydailycustomerrequirement.PutaTitleanddateonmapandincludeCustomerRequirementsMakeeveryefforttocollectgooddataUsealternatemethodsforcollectingdatawhentimeisaconstraintCompareagainstrecenthistoricaldataasasanitycheck24ValueSteamMappingMappingTipCurrentStateValueStreamMapSupplierCustomerCustomerrequirement500bladesperweek211112221CurrentStateValueStreamMapCurrentStateValueStreamMapSupplierCustomerCustomerrequirement500bladesperweekDailyDailyI2I1I1I11I22I21I60010815620817472184CurrentStateValueStreamMapCurrentStateValueStreamMap2yearForecastSupplier90dayorderWeeklyorder90Dayproductionplan2yearForecastMRPFunction90dayorderWeeklyorderCustomerDailyWeeklyScheduleDailyMeetingDailyCustomerrequirement500bladesperweekDailyDailyI2I1I1I11I22I21I60010815620817472184CurrentStateValueStreamMapCurrentStateValueStreamMap2yearForecastSupplier90dayorderWeeklyorder90Dayproductionplan2yearForecastMRPFunction90dayorderWeeklyorderCustomerDailyWeeklyScheduleDailyMeetingDailyCustomerrequirement500bladesperweekDailyDailyI2I1I1I11I22I21I60010815620817472184VARatio=0.8%CurrentStateValueStreamMapExercise:ABCForging(Sampledata)CustomerDemand???????ProductMixVolumeAVolumeBVolumeCVolumeDVolumeE=5Discs=500/yr=500/yr=500/yr=150/yr=100/yr??DeliveryScorecard??QualityConcessions=0ppm=15,000cppm(dimensional)=75%ResponseTime=70daysTransportation??DistancetoCustomer=200miDistanceHT/Insp=150miResponseTime=5dayProductionProcessOpSaw*HTC/T=15m=9h4hC/O20m1.5hInv.3511914984921Misc.20%↓time2h(Heat)8h(Cool)5%reworkScheduling?Two8-hrshifts,30minbreakpershift?5workdays/week,50weeks/year?Customerprovides2-yearforecast,60-dayflexibleschedule,weeklypullsignal?Aeroprovidessub-tiersw/2yrforecastand8-weekfirmschedule?AerousingMRPtoscheduleeachworkcenter,supervisorsexpeditedaily?Batchsizeof40piecesthroughprocess,averageleadtimeof~10weeksForge=07m*Insp=03mMach=3hInsp=1.5hPack=5m*OutsourcedOperationsExercise:ABCForging(SampleValueSteamMappingProcessInformationSheetSupplier:PartName:TimefromTimeelaspsedfinishinglastAvailableorfromfinishingonegoodpartofoneassignednumberparttofinishingproductionruntoofminutesforthenextpart(withfirstgoodpartofeachoperationinaDescriptionoftheprocessbeingperformednosetup)nextrun24hourperiodPartNo:Ave.numberofpartsrunbeforemovingallpartstonextoperationAnnualVolume:RoutingOperationNumberVendorname(outsourcedoperationsonly)CityandstatewhereoutsourcedoperationisperformedTraveldistancetooutsidevendorsMeansofconveyenceAveragetimeapartspendsateachoperationOperationDescriptionCycleTimeChange(min)Over(min)AvailableMinutesperDayBatchSizeVendorLocationDistancefromPlantMethodof(miles)TransportLeadTime(days)30ValueSteamMappingProcessInfValueSteamMappingValueStreamA