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1、Value Stream Map,WCLE Office Training Material,Page 2,Value Stream Mapping (VSM),What is a Value Stream?,Page 3,Value Stream is all the Activities (both VA and NVA) required to bring a product through from raw materials to the hands of the CustomerValue Stream Map is a standard Method for high level
2、 process Mapping,Molding,Trim,Assembly,What is a Value Stream?,Page 4,Helps to visualize/understand/highlight Material & Information Flow Helps to see Waste and Improve opportunitiesAllows everyone to gain a common understanding of the Current state (AS-IS) and the Future vision (TO-BE),Whats in It
3、for Me?,Page 5,Steps for Value Stream Mapping,4,Current VSM,Future VSM,Plan and followup,WHERE We AREWHERE TO GOHOW TO GO,Level 1Value Stream Mapping - VSM(Strategic direction),Level 2Functional mapping(Process re-engineering),Level 3Flow diagram for materials and information(Improvement of work met
4、hods),Level 1 Value Stream Mapping,Lean makes sense 精益能够做到,Process viewed by you你所见到的流程,Process in reality实际执行的流程,Targeted process精益流程,Software?,SMART!,Page 8,CURRENT LCM FLOW,Normal flow from customer to customer,Lead time between OI and delivery ready to be shipped : from 8 to 4 weeks OTIF : 85% o
5、f every line shipped,Page 9,Select product/process family,Draw current state,Create future state,Implement action plan,Steps for Value Stream Mapping,Repeat the Process,Select priority processes,Identify wastes and improvement opportunities Draw ideas directly on VSM,Draw process using pencil/eraser
6、 Collect all possible data on shop floor,TIPS,STEPS,Develop & execute a kaizen plan Review plan regularly to achieve future state,Continuous improvement,Page 10,Select product/process family,Draw current state,Create future state,Develop/execute improve,Steps for Value Stream Mapping,Repeat the Proc
7、ess,Page 11,#1 Select Product Family PQPR example,PROCESS MACHINES,To create a product family matrix, list your products and the process steps working backwards from the customer along the top. Look for common process steps that apply to several productsThese products can then be grouped into famili
8、es.,Page 12,Select product/process family,Draw current state,Create future state,Implement action plan,Steps for Value Stream Mapping,Repeat the Process,Page 13,#2 Draw Current State,Some hints: Use actual, observed data Begin at end point & proceed in reverse flow Walk the entire process first befo
9、re recording data Everyone on the team should create their own map Use pencil and paper,Page 14,#2 Draw Current State: Sample Symbols,Machining,Process Box,Data Box,I,Inventory,1,Operator,ManualInformation,Electronic Information,Inspection Point,WithdrawalKanban,Push Arrow,Customers / Suppliers,To C
10、ustomer,ProductionKanban,Supermarket,Truck Shipment,Future State Improvement,“Go See”Scheduling,DailySchedule,Schedule,Page 15,MANUFACTURINGCycle Time (machine, manual)Lead Time Queue TimeTransportation TimeChange Over time (c/o)Availability (uptime)Batch (lot) SizeQuality% (scrap rate, reworks,.)n#
11、 Operators,PROCUREMENTLT from Part Request to Purchase Ordern# of PR/PO to be processed (queue)Quality% = PO processed without errorsn# resourced used,DESIGNLT to BOM and dwg emissionn# of orders to be processed (queue)Quality% of correct BOM/dwg 1 timeDelivery% of BOM and drawing on time vs. total
12、n# resourced used per # of shiftsn# drawing changes,#2 Current State Example of data to collect,Not so necessary to be so precise, but good reference for judgment!,Page 16,Customer or SupplierProcess (ends when the flow stops),Use the following forms:,#2 Current State PROCESS & ACTIVITY INVOLVED,Pag
13、e 17,Inventory, WIPFlow of material (production push flow)Flow of finished goods or raw materialsMeans of transportation,Use the following forms:,#2 Current State MATERIAL FLOW,Page 18,wkly order,#2 CURRENT STATE Information flow,Page 19,#2 CURRENT STATE Data box,Page 20,Machine,x2,C/T 54 sec,C/O 34
14、 min,2 shifts,UT 90%,#2 CURRENT STATE Data box,Page 21,#2 CURRENT STATE Timeline of Production leadtime,Page 22,#2 CURRENT STATE Examples,By hand,Page 23,Select product/process family,Draw current state,Create future state,Implement action plan,Steps for Value Stream Mapping,Repeat the Process,Page
15、24,Is the basis of a plan towards a Lean Production System Allows full participation and buy-in of the team in developing the future vision of the business Summarize improvement needs Is a stream of value-adding flow linked to the customer by pull or continuous flow,#3 FUTURE STATE Purpose,Page 25,D
16、oes the step bring value to the customer? if not, and if possible try to eliminate step,#3 FUTURE STATE Hints to draw the vision,Is the step capable (same result every time)?if not, look the Quality process, reduce variance, ,Are process steps linked by pull, does the product flow to the next? if not implement Just In Time (from Batch to Flow, U-cell, Takt-time, Std work),
