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1、CAF STA 10/2004供應商培訓何謂精實製造(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 va
2、lue 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 户之間全面性需求措施 A value stream is all of the actions required to change raw materials into a product delivered to the customer 价值流图是什么What is
3、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 information flow 价值流图分析之利益Benefits of Value Stream Mapping*提供流動视觉的描述（以）用作零件制程程序的决策 Provides a visual depiction of flow use as part of the decision making p
4、rocess*在价值流中以提供鉴认七大浪费缘由 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 between information flow and material flow*通过价值流以作为工厂发展改善流程基础与消除浪费 Becomes the basis for developing a plan for improving flow throughout the value stream现状价
5、值流图Current state value stream mapn一个现状价值流图是为完整价值流目前存在的视觉描述。包含物料，产品，即咨询流n A current sate value stream map is the depiction of the complete value stream as it presently exists. the map inclides material, product, and information flow n虽然关注在生产制造，也可以用在描述非生产活动。n Although the focus is on the manufacturing
6、, the map could also be used to depict non-manufacturing activities 现状价值流图Current state value stream mapn评估现状 Assessing the current situationn价值流图分析第一步骤是评估现实状况以制作现状图n The first in value stream mapping is assessing the current situation by creating a current state map 现状价值流图Current state value stream
7、 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*反向跟随产品从交货，生产作业，到原料入厂n Follow the flow 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nDraw the processing steps used to process, move and stor
8、e the product 现状价值流图Current state value stream mapn*记入適當的程序与库存数据n Input the appropriate process and inventory datan*绘制咨询流n Draw the information flown*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n Draw a timeline depicting the lead time, showing value add and non-value add timeCurrent state mapping for a value stream
9、Current state mapValue stream mappingFutures state map未来价值流图future state value stream map未来价值流图是一目视可描述改善對策目标包含物料，产品，及咨询流nA future state value stream map is visual depiction of the goal of improvement actions, the map includes material, product, and information flow 未来价值流图析步骤future state value stream
10、 mapping*着手以现状价值流图鉴别消除浪费机会nBegin with the current state value streams map, use the map to identify opportunities to eliminate waste.*确认顾客需求/takt time nIdentify the customer demand rate /takt time *依计划执行（从控制缓行最小于最大水准）n follow the plan to “flow where you can, and pull (from a controlled buffer with mi
11、nimum and maximum levels ) when you cannot flow” 未来价值流图析步骤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nUse tools, such as process flow analysis,to help analyze and identify waste reduction opportunities.*确认在生产鍊单一点（制程速率点）可排生产计划nIdentify one single point in the production chain (the pace
12、maker 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nPost the map in area that is clearly visible to all work group members on a continuous basis. future state value stream mapMeasurements :衡量指标*前置时间天数是以库存依據顾客需求在各作业間，计算前置时间必须从制程浪费消除改善nLead time in days is calculated by di
13、viding inventory by customer requirements for one day for each operation, lead time should improve as waste is eliminated from the process *附加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nValue-add time in seconds is calculated by timing the operation as it changes form, fit, or finish of th
14、e product. value add time will be the same in both the current and future sate unless process is changed future state value stream mapMeasurements :衡量指标*指标nDock to dock (DTD)nBuild to schedule (BTS)nFirst time through (FTT)nOverall equipment effectiveness (OEE), ntotal Cost*工作小组未来状况对策绩效必须由改善数据反应nThe
15、 effectiveness of work group future state actions should be reflected by an improvement in these metrics价值流图析*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*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
16、价值流图析*价值流是为产品已当前通过其基本生产过程所进行的全部活动，可分成n .从原材料到产品交到顾客手中n “生产流”n .从概念到投产n “设计流”价值流图析n*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n (关键问题)n*分析检讨，关键问题，提出改善对策后，再次绘制一期望的，未来状態的价值流图，作为目标蓝图及执行改善活动生產管理生產排程MPS顧客協力廠商採購MRP物料?人力?優先順序?人員是否足夠時間拖延生產部品塗裝部門物料是否足夠時間拖延催料需要物料庫存庫存不準確的顧客訂單不具信賴的製程及供應商交貨單不及時、不正確的庫存回報价值流图析基本功能*价值流图析可以帮助你看到的不仅仅是单一的生产制程而是整体的生产流程*价值流图析可以帮助你发现生产制程中的浪费的根源*价值流图可以为生产过程提供共同语言*价值流图可显示讯息流与材料流的联系*没有其他工具能做到此项功能价值流图析基本功能*价值流图是为实现精实生产的蓝图以作为改善实施计划的基础*如果要设计一个新的生产制程或者要改变一个现有的价值流就将精实生产理论概念与技术实务结合*进行价
