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1、ENERGIZER SCHICK - HIGHLY CONFIDENTIAL - RESTRICTED FOR INTERNAL USE ONLY,1,Lean Manufacturing Value Stream Mapping,ENERGIZER SCHICK - HIGHLY CONFIDENTIAL - RESTRICTED FOR INTERNAL USE ONLY,2,What is Lean?,Lean is a that focuses on: Creating value for the Customer Eliminating Waste Continuous increm
2、ental improvement,Thinking Process,ENERGIZER SCHICK - HIGHLY CONFIDENTIAL - RESTRICTED FOR INTERNAL USE ONLY,3,What is a Value Stream?,“All of the actions, value or non value added that are required to bring a product from concept to launch or from raw material order to delivery. . . ”,From “Lean Le
3、xicon”,ENERGIZER SCHICK - HIGHLY CONFIDENTIAL - RESTRICTED FOR INTERNAL USE ONLY,4,Order Fulfillment Value Stream,Ideally, wed want the materials, information and cash to flow smoothly (without interruption) and as quickly as possible through this stream.,ENERGIZER SCHICK - HIGHLY CONFIDENTIAL - RES
4、TRICTED FOR INTERNAL USE ONLY,5,Lean Elements,Value Stream = Value Providing Processes,Pull,Perfection,Flow,Value,ENERGIZER SCHICK - HIGHLY CONFIDENTIAL - RESTRICTED FOR INTERNAL USE ONLY,6,Value,“What is the willing to Pay for?” 3 Types of Customers: The external end-user or paying customer The dow
5、nstream customer of any internal upstream process. Your company as the customer of external suppliers.,Customer,ENERGIZER SCHICK - HIGHLY CONFIDENTIAL - RESTRICTED FOR INTERNAL USE ONLY,7,Flow,Ideal flow = 1 piece at a time Rate determined by customer demand - Takt time Work balanced for each person
6、 or machine Travel distance for materials & people minimized Standard Work utilized Flow what you can Pull what you cant Requires that all steps in the process be: Capable = Right every time Available = Always able to run Adequate = Capacity to avoid bottlenecks,ENERGIZER SCHICK - HIGHLY CONFIDENTIA
7、L - RESTRICTED FOR INTERNAL USE ONLY,8,Phases of Lean Journey,Phase 1-Identify/Map Value Streams Phase 2-Prioritize opportunities Phase 3-Utilize Lean tools to eliminate waste Phase 4-Control the flow Phase 5-Lean metrics Phase 6-Re-evaluate Value Streams and begin again,ENERGIZER SCHICK - HIGHLY CO
8、NFIDENTIAL - RESTRICTED FOR INTERNAL USE ONLY,9,It All starts with Waste Identification,Identify all forms of Waste throughout our entire Value Stream before: Reducing the waste or Eliminating the waste This will enable us to prioritize our efforts and focus on the high potential events first.,ENERG
9、IZER SCHICK - HIGHLY CONFIDENTIAL - RESTRICTED FOR INTERNAL USE ONLY,10,8 Wastes,Overproduction Inventory Waiting Transporting Unnecessary processing Unnecessary motion Defects Under utilization of people,ENERGIZER SCHICK - HIGHLY CONFIDENTIAL - RESTRICTED FOR INTERNAL USE ONLY,11,Over-Production,Pr
10、oducing more than what the customer really wants.,Ways to Overcome: Reduce setup times Synchronize time and amount of processes Create compact layouts and visibility,ENERGIZER SCHICK - HIGHLY CONFIDENTIAL - RESTRICTED FOR INTERNAL USE ONLY,12,Inventory,Excess inventory requires handling, space, $, p
11、eople, and paperwork.,Ways to Overcome: Synchronize work flow to reduce accumulation Shorten setup time Reduce lead time Cellular layouts Zero Quality Defects Reducing all other wastes reduces the waste of inventory,ENERGIZER SCHICK - HIGHLY CONFIDENTIAL - RESTRICTED FOR INTERNAL USE ONLY,13,Waiting
12、,Waiting for upstream processes due to poor layout, unbalanced work load or equipment downtime.,Ways to Overcome: Synchronize work flow Balance uneven loads by flexible workers and equipment Implement preventive maintenance to eliminate machine down-time,ENERGIZER SCHICK - HIGHLY CONFIDENTIAL - REST
13、RICTED FOR INTERNAL USE ONLY,14,Transportation,Transportation adds No value to the product. Rather than improve the transportation: Reduce it Eliminate it.,Ways to Overcome: Establish layout and locations which reduces or eliminates transportation,ENERGIZER SCHICK - HIGHLY CONFIDENTIAL - RESTRICTED
14、FOR INTERNAL USE ONLY,15,Unnecessary Processing,Same data entered into 3 different information systems. (SAP, Access, Excel),All unnecessary, or Non- Value Added, processing steps should be eliminated,Ways to Overcome: Question if process is necessary at all Simplify Use Standard Work Reduce Handoff
15、s/approvals,ENERGIZER SCHICK - HIGHLY CONFIDENTIAL - RESTRICTED FOR INTERNAL USE ONLY,16,Unnecessary Motion,Motion of people, machines, and products is waste.,Ways to Overcome: Study motion and eliminate or reduce motion through improved layouts. Cellular Manufacturing Rethink material storage Job/T
16、ask Combinations,ENERGIZER SCHICK - HIGHLY CONFIDENTIAL - RESTRICTED FOR INTERNAL USE ONLY,17,Defects (Correction),Making defective product is pure (muda) waste. Focus on preventing defects Not finding and repairing defects,Ways to Overcome: Mistake-proof to prevent defects Never Pass defects Standard Work,ENERGIZER SCHICK - HIGHLY CONFIDENTIAL - RESTRICTED FOR INTERNAL USE ONLY,18,Waste of Underutilizing People,The eighth waste is not fully utilizing the time a
