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1、CAF STA 10/2004供應商培訓,精实生产 衡量指标/价值流分析,何謂精實製造(Lean Mfg),它是什麼? 是一種在價值流(value stream)中藉由排除浪費以提昇流動性，使其能獲致更短的前置時間，從而提供高品質、低成本的製造哲學 由產品開發、程序工程、營運管理及企業總管理作業等所組成的一整合性系統，其能為顧客提供價值及帶給人們尊嚴 它不是什麼? 僅是裁減員額數,精實製造的精神 (Lean Manufacturing),精實製造觀念是消除浪費，來縮短顧客下訂單到交貨時的時間,產品交貨,顧客下訂單,時間,傳統製造,精實製造,產品交貨,顧客下訂單,時間(縮短),浪費,价值流图分析
2、,课程目标 Objectives,在完成此一课程你将能 At the end of this section, you will be able to : *定义期间价值流及价值流图分析 Define the terms Value stream and value stream Mapping *應用价值流图分析实施步骤以模拟精实 Apply the steps for Mapping a Value Stream to the Lean Simulation,价值流是什么What is Value Stream,定义 Definition 价值流是將生产物料改变到产品运交给客 户之間全面性
3、需求措施 A value stream is all of the actions required to change raw materials into a product delivered to the customer,Value stream mapping,价值流图是什么What is Value Stream Map,定义 Definition . 一个目视化以描述整体价值流， 包含原材料/产品及咨訊流分析图 A visual depiction of the complete value stream, including material, product, and in
4、formation flow,价值流图分析之利益Benefits of Value Stream Mapping,*提供以视觉的描述方式,作零件制造程序的决策 Provides a visual depiction of flow use as part of the decision making process *在价值流中以辨认七大浪费的來源 Allows for identification of the sources of the seven wastes in the value stream *验证咨询流与材料流的關连性 Demonstrates the linkage bet
5、ween information flow and material flow *通过价值流为正在发展中的改善流程計劃作基础 Becomes the basis for developing a plan for improving flow throughout the value stream,现状价值流图Current state value stream map,现状价值流图是描述目前存在的完整价值流。包含物料，产品，即咨询流 A current sate value stream map is the depiction of the complete value stream as
6、 it presently exists. the map include material, product, and information flow 虽然主要在生产制造上，也可以用在描述非生产活动。 Although the focus is on the manufacturing, the map could also be used to depict non-manufacturing activities,Current state map,现状价值流图製作 Current state value stream map,现状评估 Assessing the current si
7、tuation 价值流图分析第一步骤是评估现在状况以 制作现状图 The first in value stream mapping is assessing the current situation by creating a current state map,现状价值流图製作Current state value stream map,*选择一产品或产品族 Choose a product or product family *描述顾客需求 Depict the customer requirements *依據产品流程从交货，生产作业，反向到原料入厂為止 Follow the flo
8、w of the product from shipping, working backwards to the where raw materials arrive in the plant *绘制产品在使用的過程,移动与储存阶段程序 Draw the processing steps used to process, move and store the product,现状价值流图製作Current state value stream map,*记入適當的程序与库存数据 Input the appropriate process and inventory data *绘制咨询流 Dr
9、aw the information flow *绘制时间线描述前置时间，表示出有附加值 与无附加值时间 Draw a timeline depicting the lead time, showing value add and non-value add time,Current state mapping for a value stream,未来价值流图future state value stream map,未来价值流图是一個描述可以實施改善對策的目标,這圖形包含物料，产品，及咨询流 A future state value stream map is visual depicti
10、on of the goal of improvement actions, the map includes material, product, and information flow,Futures state map,未来价值流图分析步骤future state value stream mapping,*着手以现状价值流图鉴别消除浪费机会 Begin with the current state value streams map, use the map to identify opportunities to eliminate waste. *确认顾客需求/takt time
11、 Identify the customer demand rate /takt time *依计划执行到”那個地方你能改善那個地方不能改的”（从控制最小與最大水准之間的緩衝） follow the plan to “flow where you can, and pull (from a controlled buffer with minimum and maximum levels ) when you cannot flow”,未来价值流图分析步骤future state value stream mapping,*使用工具如流程分析以协助分析及鉴别浪费降低的机会 Use tools,
12、 such as process flow analysis, to help analyze and identify waste reduction opportunities. *确认单一点在生产鍊（制程速率点）可排生产计划 Identify one single point in the production chain (the pacemaker process “)where you will schedule production *张贴价值流图在作业区给全部工作人员清楚目视為持续改进的基础 Post the map in area that is clearly visibl
13、e to all work group members on a continuous basis.,future state value stream mapMeasurements :衡量指标,*前置时间的天数是库存依據顾客在每個作业一天的需求計算的.计算前置时间必须从改善制程浪费消除 Lead time in days is calculated by dividing inventory by customer requirements for one day for each operation, lead time should improve as waste is elimin
14、ated from the process *附加價值时间秒数是由作业时间计算，如变更外形 安装，或产品修饰，附加价值时间将相同于现在与未来状况除非制程被变更 Value-add time in seconds is calculated by timing the operation as it changes form, fit, or finish of the product. value add time will be the same in both the current and future sate unless process is changed,future stat
15、e value stream mapMeasurements :衡量指标,*指标 Dock to dock (DTD) Build to schedule (BTS) First time through (FTT) Overall equipment effectiveness (OEE), total Cost *工作小组未来状况对策绩效必须由改善数据反应 The effectiveness of work group future state actions should be reflected by an improvement in these metrics,价值流图析以益處,*
16、价值流图析是一种完整且有系统性的方法 *使用价值流图析之意义是可在巨观的大范圍下作业。亦可拘於局部性.區域性.或個別性的作業. *因此他是可进行全面整体性而不仅是最佳化个别部分。,价值流图析益處,*一个价值流图析是指归集一产品在其生产过程中所有的活动：包括哪些有增加附加價值及没有增加价值的活动。 *价值流图析将是包含有附加值作业与无附加值作业调查检讨，用以改善制程提升整体生产力的一项系统手法,价值流图析,*价值流是为产品以当前通过其基本生产过程所进行的全部活动，可分成 .从原材料到产品交到顾客手中 “生产流” .从概念到投产 “设计流”,价值流图析,*从顾客到供应商跟随产品的生产反向路径将材料流与讯息流以代表图形仔细绘出每個过程以便于了解掌握制程中的 (关键 问题) *分析检讨，关键问题，提出改善对策后，再次绘制一期望的，未来状態的价值
