Value Stream Mapping 值流绘图值流绘图Kaizen!ActionRespWhenBenefit我该如何开始我该如何开始LEAN训练？训练？1 VSM介绍介绍•LEI和TSSC的源由•VSM的历史•VSM目的•介绍VSM，让学员在工作上能应用VSM•建立值流图，提供有用的信息给主办单位•发展学员鉴别值流中浪费的能力•帮助学员了解，LEAN工具如何结合，来协助我们达成工作目标•欢迎随时发问!2 第一章第一章 – 值流绘图程序值流绘图程序Value Stream Mapping3 什么是什么是VSM？？•什么是值流？值流包括了完成某一种产品或服务所必须要的所有所有程序步骤(加值和非加值)•什么是值流绘图？值流绘图是一种将物流物流和信息流信息流可视化视化的方法，用以协助我们完成产品或服务4 值流改进值流改进&过程改进过程改进值流=由原材料开始到交货给顾客，所需要的步骤，包括加值和非加值的步骤Value Stream值流值流STAMP压字压字MACHINE车削车削ASSEMBLE装配装配PROCESS 过程过程 PROCESS 过程过程 PROCESS 过程过程RawMaterial 原料FinishedProduct 成品Customer顾客5 值流的描绘值流的描绘跟随产品从结束结束回溯至开始开始的生产过程，并利用物流物流和信息流信息流的图标(现况图)来描绘出可目视可目视的图像接着绘出未来图，以显示应有的价值流动价值流动6 Information FlowP/T 1226 s DistributiondailySewing3ShippingFinal Assembly2I1800 pcs Suppliers.Fabric WeeklyOther Bi-WeeklyProduction ControlWeeklyOrders5 weekForecastWeeklyOrdersWeekly ScheduleDaily ShiplistFabricFabric Cut3000 pcs650 pcsUpholstry6295 pcs600 pcsFrame AssyFoam AssyI2000 pcs800 pcs785 pcsFramesMCT = 60 secC/O = 20 minOCT = 150 secC/O = 2 minOCT = 501 secC/O = 0 minOCT = 395 secC/O = 0 minOCT = 60 secC/O = 0 minOCT = 60 secC/O = 0 minIIII1000 chairs/wk1 ShiftIIFlow RacksF/G WarehouseTicketsMaterial Flow10 d 120 s 15 d 4 d 1.5 d 3 d L/T 33.5 d 210 s 501 s 395 s TimelineT/T=135s7 第二章第二章 – 建立现况图建立现况图Value Stream Mapping8 “高地公司高地公司”生产制造的数据表生产制造的数据表实例研究的数据表在手册的附录D利用“高地公司” 的数据表做实例研究检讨9 Manchester Avenue1x daily18, 400 pcs/mo-12,000 “L”-6,400 “R”Tray = 20 pcs2 shiftsTT = 60 sec.10 •在制程前或后有库存•在俩制程间没有实现一件流.•交接•如果是一件流交接, 就不要增加另一个制程方框•如果职能之间的交接打断了流程, 就要增加制程方框 确定过程方框确定过程方框11 ManchesterAvenue1x dailyStamp Machine Weld Sub-Assembly Assembly Shipping18, 4000 pcs/mo-12,000 “L”-6,400 “R”Tray = 20 pcs2 shiftsTT = 60 sec.SR12 ManchesterAvenue1x daily18, 4000 pcs/mo-12,000 “L”-6,400 “R”Tray = 20 pcs2 shiftsTT = 60 sec. Stamp Machine Weld Sub-Assembly Assembly ShippingSR13 Data Box & Process Box Definitions And SymbolsThe Below Data Gets Added To Or Above the Process Box下列数据记录于程序盒内或上方下列数据记录于程序盒内或上方Shared Resource (Shared if the resource is used by other value streams) 共享资源……………………………………….SRNumber Of Operators 操作员人数……………………………………………………………………………………………=#Number Of Shifts This Process Is Run 执行此程序时的班别数……………………………………………………………….. SH=#Takt Time ( Shown one time in/near the customer Data Box) 客户需求时间………………………………………..………… T/T=TimeNote: The Following Information Goes In the Data Box below the Process Box下列信息记录于程序盒下方的数据盒内下列信息记录于程序盒下方的数据盒内Operator Cycle Time 操作员周期时间…………………………………………………………………………………………OCT=TimeMachine Cycle Time 机器周期时间……………………………………………………………………………………………MCT=TimeDrop Off Rate (How often a finished part is completed off the end of the process) 产出率………………….…...…………..D/R=TimeProcess Lead Time (Time required to complete a batch through a process) 程序前置时间……………………...……………PLT=TimeBatch Size (Size of the batch through a process when greater than one piece) 披量……………………..……...…… … ……BATCH=PiecesProcess Time Per Piece (Process lead-time divided by batch size) 单件程序时间………………………………..……………PTP=TimeReject Rate (Percent of product that is rejected for quality defects) 不良率………………… … …………..……..….……..REJ=%Uptime (Percent of planned time the process runs, takes out breakdowns & unplanned maintenance) 操作率…...……………U/T=%Changeover Time (Time to change from the last good piece of part A to the first good piece of part B) 换模时间…............C/O=TimeEvery Part Every_____ (How often every part number is run through the process, Setup Wheel)生产循环时间... ............ .....EPE=TimePitch Interval (How often the container quantity is completed) 间距时间………………………………………...……..…...PITCH=TimeProcess Boxt程序盒程序盒NOTE:Only place appropriate data in the data box.The list above may not be totally inclusive.Data Box资料盒资料盒数据盒只记录实际需要的数据，不一定数据盒只记录实际需要的数据，不一定要记录上面的全部信息要记录上面的全部信息14 This is a manual process. Assembly, manual machining, load/unload… Put this time into the Process Capacity Chart under OCT to calculate the capacity of this operation. 这是人工时间，例如：装配、人工车削、上料/下料...。
这一类的时间，在计算此一加工作业的产能时，被归类为程序产能表的操作员周期时间OCT 操作员周期时间TimeMCT 机器周期时间This is an automatic process. Stamping machine, automatic molding machine, milling… Put this time into the process capacity chart under MCT to calculate the capacity of this machine这是机器时间，例如：压字机、自动铸模机、研磨...这一类的时间，在计算此一加工作业的产能时，被归类为程序产能表的机器周期时间TimeOCT 操作员周期时间MCT 机器周期时间This is a manual process triggering an automatic process. Loading time + automatic time, test equipment, manual unload and restart of die-cast… If the operator can be separated from the machine, record the OCT and MCT on separate lines. If the operator is tied to the machine, put the total time (OCT+MCT) in the process capacity chart.这是人工过程触发机器过程，例如：上料时间+机器加工时间、测试设备、人工上料并开始压铸...。
如果能够将操作员与机器分离，就要把操作员周期时间和机器周期时间记录在不同的轴如果无法将操作员与机器分离，就把总时间(操作员周期时间+机器周期时间)记录在程序产能表上TimeDefinition Of Processes And Times 程序和时间的定义15 1x daily18, 4000 pcs/mo-12,000 “L”-6,400 “R”Tray = 20 pcs2 shiftsManchesterAvenueOCT = 40 secD/R = 40 secC/O = 0REJ = 7%U/T = 100%2Shifts27,600 sec. Avail.1TT = 60 sec.Stamp Machine Weld Sub-Assembly Assembly ShippingSR16 ShippingManchesterAvenueMCT = 1 secondC/O = 1 hourREJ = 3%U/T = 85%EPE = 2 weeks27,600 sec. AvailStamp1x dailyMachine1Weld1Sub-Assembly1Assembly1OCT = 39 secD/R = 39 secC/O = 10 minREJ = 4%U/T= 100%2 Shifts27, 600 sec Avail.OCT = 62 secD/R = 62 secC/O = 0REJ = 6%U/T =100%2 Shifts27, 600 sec. Avail.OCT = 46 secD/R = 46 secC/O = 10 minREJ = 5%U/T = 80%2 Shifts27,600 sec. Avail.OCT = 40 secD/R = 40 secC/O = 0REJ = 7%U/T = 100%2Shifts27,600 sec. Avail.18,400 pcs/mo -12,000 “L”-6,400 “R”Tray = 20 pcs2 ShiftsTT = 60 sec.200 tSR17 ShippingMCT = 1 secondC/O = 1 hourREJ = 3%U/T = 85%27,600 sec. avail.EPE = 2 weeksStamp200 t1x dailyMachine1OCT = 39 secD/R = 39 secC/O = 10 minREJ = 4%U/T= 100%2 Shifts27, 600 sec Avail.Weld1Sub-Assembly1Assembly1OCT = 62 secD/R = 62 secC/O = 0REJ = 6%U/T =100%2 Shifts27, 600 sec. Avail.OCT= 40 secD/R = 40 secC/O = 0REJ = 7%U/T = 100%2Shifts27,600 sec. Avail.OCT = 46 secD/R = 46 secC/O = 10 minREJ = 5%U/T = 80%2 Shifts27,600 sec. Avail.18,400 pcs/mo -12,000 “L”-6,400 “R”Tray = 20 pcs2 ShiftsICoils5 daysI4600 L2400 RI1100 L600 RI1200 L640 RI1600 L850RI2700 L1440 RHighland ManufacturingSheet Metal HousingsCurrent State(Date)ManchesterAvenueTT = 60 sec.SR18 ICoils5 daysI4600 L2400 RI1100 L600 ROCT = 62 secD/R = 62 secC/O = 0REJ = 6%U/T =100%2 Shifts27, 600 sec. Avail.OCT = 40 secD/R = 40 secC/O = 0REJ = 7%U/T = 100%2 Shifts27,600 sec. Avail.ShippingStagingII1600 L850 R1200 L640 R2700 L1440 RFerrousMetals Co.500 ft coilsTues &ThursMachine1OCT = 39 secD/R = 39 secC/O = 10 minREJ = 4%U/T= 100%2 Shifts27, 600 sec Avail.MCT = 1 secondC/O = 1 hourREJ = 3%U/T = 85%27,600 sec. avail.EPE = 2 weeksStamp200 tWeld1OCT = 46 secD/R = 46 secC/O = 10 minREJ = 5%U/T = 80%2 Shifts27,600 sec. Avail.1x dailySub-Assembly1Assembly118,400 pcs/mo -12,000 “L”-6,400 “R”Tray = 20 pcs2 ShiftsHighland ManufacturingSheet Metal HousingsCurrent State(Date)IManchesterAvenueTT = 60 sec.SR19 ICoils5 daysI4600 L2400 ROCT = 62 secD/R = 62 secC/O = 0REJ = 6%U/T =100%2 Shifts27, 600 sec. Avail.OCT = 40 secD/R = 40 secC/O = 0REJ = 7%U/T = 100%2 Shifts27,600 sec. Avail.ShippingStagingIII1600 L850 R1200 L640 R2700 L1440 RFerrousMetals Co.500 ft coilsTues &ThursMachine1OCT = 39 secD/R = 39 secC/O = 10 minREJ = 4%U/T= 100%2 Shifts27, 600 sec Avail.MCT= 1 secondC/O = 1 hourREJ = 3%U/T = 85%27,600 sec. avail.EPE = 2 weeksStamp200 tWeld1OCT = 46 secD/R = 46 secC/O = 10 minREJ = 5%U/T = 80%2 Shifts27,600 sec. Avail.1x dailySub-Assembly1Assembly16-weekForecastWeeklyfaxProductionControl90/60/30 dayForecastsDailyOrder18,400 pcs/mo -12,000 “L”-6,400 “R”Tray = 20 pcs2 ShiftsHighland ManufacturingSheet Metal HousingsCurrent State(Date)I1100 L600 RManchesterAvenueTT = 60 sec.SR20 ICoils5 daysI4600 L2400 RI1100 L600 ROCT = 62 secD/R = 62 secC/O = 0REJ = 6%U/T =100%2 Shifts27, 600 sec. Avail.OCT = 40 secD/R = 40 secC/O = 0REJ = 7%U/T = 100%2Shifts27,600 sec. Avail.ShippingStagingIII1600 L850 R1200 L640 R2700 L1440 RFerrousMetals Co.500 ft coilsTues &ThursMachine1OCT = 39 secD/R = 39 secC/O = 10 minREJ = 4%U/T= 100%2 Shifts27, 600 sec Avail.MCT = 1 secondC/O = 1 hourREJ = 3%U/T = 85%27,600 sec. avail.EPE = 2 weeksStamp200 tWeld1OCT = 46 secD/R = 46 secC/O = 10 minREJ = 5%U/T = 80%2 Shifts27,600 sec. Avail.1x dailySub-Assembly1Assembly1Weekly Schedule18,400 pcs/mo -12,000 “L”-6,400 “R”Tray = 20 pcs2 ShiftsHighland ManufacturingSheet Metal HousingsCurrent State(Date)TT = 60 sec.ManchesterAvenue6-weekForecastWeeklyfaxProductionControlMRP90/60/30 dayForecastsDailyOrderSR21 ICoils5 daysI4600 L2400 RI1100 L600 ROCT = 62 secD/R = 62 secC/O = 0REJ = 6%U/T =100%2 Shifts27, 600 sec. Avail.OCT = 40 secD/R = 40 secC/O = 0REJ = 7%U/T = 100%2 Shifts27,600 sec. Avail.ShippingStagingIII1600 L850 R1200 L640 R2700 L1440 RFerrousMetals Co.500 ft coilsTues &ThursMachine1OCT= 39 secD/R = 39 secC/O = 10 minREJ = 4%U/T= 100%2 Shifts27, 600 sec Avail.MCT= 1 secondC/O = 1 hourREJ = 3%U/T = 85%27,600 sec. avail.EPE = 2 weeksStamp200 tWeld1OCT = 46 secD/R = 46 secC/O = 10 minREJ = 5%U/T = 80%2 Shifts27,600 sec. Avail.1x dailySub-Assembly1Assembly1MRP18,400 pcs/mo -12,000 “L”-6,400 “R”Tray = 20 pcs2 ShiftsHighland ManufacturingSheet Metal HousingsCurrent State(Date)Daily ShipScheduleWeekly ScheduleTT = 60 sec.ManchesterAvenue6-weekForecastWeeklyfaxProductionControlMRP90/60/30 dayForecastsDailyOrderSR22 ICoils5 daysI4600 L2400 RI1100 L600 ROCT = 62 secD/R = 62 secC/O = 0REJ = 6%U/T =100%2 Shifts27, 600 sec. Avail.OCT = 40 secD/R = 40 secC/O = 0REJ = 7%U/T = 100%2 Shifts27,600 sec. Avail.ShippingStagingIII1600 L850 R1200 L640 R2700 L1440 RFerrousMetals Co.500 ft coilsTues &ThursMachine1OCT= 39 secD/R = 39 secC/O = 10 minREJ = 4%U/T= 100%2 Shifts27, 600 sec Avail.MCT= 1 secondC/O = 1 hourREJ = 3%U/T = 85%27,600 sec. avail.EPE = 2 weeksStamp200 tWeld1OCT = 46 secD/R = 46 secC/O = 10 minREJ = 5%U/T = 80%2 Shifts27,600 sec. Avail.1x dailySub-Assembly1Assembly1MRP18,400 pcs/mo -12,000 “L”-6,400 “R”Tray = 20 pcs2 ShiftsHighland ManufacturingSheet Metal HousingsCurrent State(Date)Daily ShipScheduleWeekly ScheduleTT = 60 sec.ManchesterAvenue6-weekForecastWeeklyfaxProductionControlMRP90/60/30 dayForecastsDailyOrder5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days 1 sec. 39 sec. 46 sec. 62 sec. 40 sec.SR23 ICoils5 daysI4600 L2400 RI1100 L600 ROCT = 62 secD/R = 62 secC/O = 0REJ = 6%U/T =100%2 Shifts27, 600 sec. Avail.OCT = 40 secD/R = 40 secC/O = 0REJ = 7%U/T = 100%2 Shifts27,600 sec. Avail.ShippingStagingIII1600 L850 R1200 L640 R2700 L1440 RFerrousMetals Co.500 ft coilsTues &ThursMachine1OCT= 39 secD/R = 39 secC/O = 10 minREJ = 4%U/T= 100%2 Shifts27, 600 sec Avail.MCT = 1 secondC/O = 1 hourREJ = 3%U/T = 85%27,600 sec. avail.EPE = 2 weeksStamp200 tWeld1OCT = 46 secD/R = 46 secC/O = 10 minREJ = 5%U/T = 80%2 Shifts27,600 sec. Avail.1x dailySub-Assembly1Assembly1MRP18,400 pcs/mo -12,000 “L”-6,400 “R”Tray = 20 pcs2 ShiftsHighland ManufacturingSheet Metal HousingsCurrent State(Date)Daily ShipScheduleWeekly ScheduleTT = 60 sec.ManchesterAvenue6-weekForecastWeeklyfaxProductionControlMRP90/60/30 dayForecastsDailyOrder5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days1 sec. 39 sec. 46 sec. 62 sec. 40 sec.Lead Time= 23.6 daysProcess Time= 188 secSR24 0s39s46s62s40sTakt time60 seconds客户需求时间客户需求时间60秒秒Stamp Machine Weld Sub-assy Assy(auto-feed)操作员负荷图操作员负荷图25 Cycle Time(OCT, MCT, Or OCT+MCT) 周期时间周期时间 Time Available (From Takt Time Calculation) 可用时间可用时间VSM Process Capacity = Use the below form (available on under DBS Office, Tools, Lean, VSM) to calculate and record VSM Process Capacity.Daily Demand:92007-May-03Operating Secs/Shift: 27600HousingsVSM TEAMStepProcessOCTMCTCapacityNumberDescription and shiftsTime (sec.)Time (sec.)Per Day (pcs)1Stamp – 1 sh - 10 secs to account for other value streams01027602Machine – 2 Sh39014153Weld – 2 sh46012004Sub-Assembly – 2 sh6208905Assembly – 2 sh4001380 You may want to record the manual time as one step, and the automatic time as another stepif the operator can be separated from the machine to see what the true current capacity is.VSM Process Capacity SheetDate Prepared: Value Stream: Completed By:Number of Shifts: 226 现状价值流绘图警示现状价值流绘图警示•避免过分详细避免过分详细. VSM是从一万米是从一万米(或适当的或适当的)高空看制程高空看制程.•要从不同的角度去问要从不同的角度去问. 这可以发现更多浪费这可以发现更多浪费或隐藏工厂或隐藏工厂.•不要问是与否的问题不要问是与否的问题.•详细说明行政过程的不良率详细说明行政过程的不良率. 它在行政过程它在行政过程价值流中是不容易被理解的价值流中是不容易被理解的.•不要急不可待地纠正程序不要急不可待地纠正程序. 改善计划是确定改善计划是确定改进路线的载体改进路线的载体.27 第三章第三章 – 精实值流精实值流Value Stream Mapping28 8 Wastes 八大八大浪费浪费ZZZZZZZWaiting等待1,2,3,4,5,6Overproduction超量生产1stUnused Creativity忽视创意xQuality Defects品质不良RUSH!Water SpiderTransportation搬运Motion不必要的动作Inventory库存De-BurringProcess多余的制程29 精实值流的概念精实值流的概念1.遵循值流来重新架构组织2.按客户需求时间生产3.尽可能发展一件流4.缩短换模时间和小批量运行5.在无法执行一件流的地方使用超市拉引系统6.只对值流中的一个过程发出生产排程7.引导点的生产数量平稳化8.引导点的混杂产品平稳化9.主要績效指标10.持续改善的领导力30 1. 遵循值流来重新架构组织遵循值流来重新架构组织CustomerProcess 1Process 2Process 3KAIZENKAIZEN提供集中的领导力建立重点是产品族减少发生事倍功半的情况正确地分配资源31 2. 按客户需求时间生产按客户需求时间生产契合顾客的需要减少超量生产的机会激励规范的产生.依照顾客声音来配置和生产TAKT TimeStandard WIPWork SequenceRF452361214378562341Elements of Standard Work32 One per Day要照着客户需求时间来拉引，不要因为空间和产能足够而推挤Don’t Produce 7 units once per weekwhen the customer wants 1 per day.当顾客需要一天一部时，不要一星期给七部当顾客需要一天一部时，不要一星期给七部1 1DayDay1 1DayDayTaktTime=1DayTaktTime=1Day客户需求时间客户需求时间 = 一天一天Shingijutsu Co., Ltd.33 3. 尽可能发展一件流尽可能发展一件流持续附加价值持续附加价值RawMat’l原料$ $$ $$$$$$$$Finished Goods成品成品一件流的浪费比批量程序少品质问题较快被看到操作员成为多能工前置时间较短34 StampingMachiningWeldingAssemblyMaterialScheduleScheduleSchedule加工时间：分钟 前置时间：星期Order订单Cash现金批量生产批量生产大量、提前推挤、各自为政大量、提前推挤、各自为政大量生产的目标：愈多、愈快就愈好Schedule35 4. 在无法执行一件流的地方使用超市在无法执行一件流的地方使用超市拉引系统拉引系统用拉引取代推挤减少超量生产较短的前置时间和较少的库存那一个运转的比较顺畅那一个运转的比较顺畅？？PushingPulling36 两种两种看板看板卡的运行卡的运行系统系统SupplyingProcessCustomer processAproduct产品Bwithdraw提取Supermarket 超市超市“Production” Kanban 生产看板“Transport” Kanban 运输看板1.当有需要时，客户程序到超市位置拉取所需要的产品当有需要时，客户程序到超市位置拉取所需要的产品2.供应程序依据生产看板，补充产品至超市位置供应程序依据生产看板，补充产品至超市位置3.如果客户直接由超市拉走需要的产品，则不需要运输看板如果客户直接由超市拉走需要的产品，则不需要运输看板ABC客户程序供应程序37 5. 缩短换模时间和小批量运行缩短换模时间和小批量运行容易配合顾客的混合性需求降低超量生产前置时间较短较少的库存件数和空间38 8. 混杂产品平稳化混杂产品平稳化有弹性地符合顾客需求减少超量生产前置时间较短较少的库存件数和空间A B A C A B A C A B A C …..39 混合生产混合生产Assembly ScheduleMonday400 ATuesday100 A, 300 BWednesday 200 B, 200 CThursday400 CFriday 200 C, 200 AordersStamping Dept.???AANo GoodMonday:140 A, 100 B 160 CBetter: Every Part Every DayEven Better: Every Part Every Window50B 70A 80C 50B 70A 80C Monday引导点需要几乎等于零的换引导点需要几乎等于零的换模时间和经常换模模时间和经常换模40 CCHeijunka box 平准盒平准盒看板由左至右，依序置于相对应的间距时间格子内One rowperproducttype 8:008:108:208:308:408:509:009:10TypeA TypeB TypeC ABABABOne column per pitch. Here pitch = 10 min.kanban41 9. (KPI’s). 主要绩效指标主要绩效指标提供明确的目标显示进度和影响 不度量就无法改进42 10. 持续改善的领导力持续改善的领导力由政策布署来推动藉由值流来组织ProblemsProblemsProblemsProblemsKaizen!ActionRespWhenBenefit KPI Board Safety Quality Delivery Cost 43 第第四四章章 – 建立未来图建立未来图Value Stream Mapping44 绘制未来图时应考虑的议题绘制未来图时应考虑的议题1.客户需求时间为何？2.值流只建立到成品超市为止或者是要一直连贯到客户订单？3.在那里执行一件流？4.引导程序在那里？5.那些是程序不连贯而可以使用超市拉引系统的地方？ 6.在引导点该如何做生产排程及提取，才能将数量及混杂产品平稳化？7.为了达到未来状态，必须执行的改善活动、项目和LEAN工具是什么？8.改善活动和项目的优先级为何？45 Transport Kanban运输看板Signal Kanban讯号看板Kanban Post看板布告FIFOSupermarket超市Withdrawal提取“First-in-First-Out”flow先进先出Max frequencySMEDTPM“Kaizen LightningBurst”改善的闪光爆发0X0XKanban ArrivingIn Batches看板以批次抵達Leveling Mix and/or Volume混合平穩化/數量平穩化 Kanban path看板路線Production Kanban生产看板Future State Icons未来状态的符号未来状态的符号46 ICoils5 daysI4600 L2400 RI1100 L600 ROCT = 62 secD/R = 62 secC/O = 0REJ = 6%U/T =100%2 Shifts27, 600 sec. Avail.OCT = 40 secD/R = 40 secC/O = 0REJ = 7%U/T = 100%2 Shifts27,600 sec. Avail.ShippingStagingIII1600 L850 R1200 L640 R2700 L1440 RFerrousMetals Co.500 ft coilsTues &ThursMachine1OCT= 39 secD/R = 39 secC/O = 10 minREJ = 4%U/T= 100%2 Shifts27, 600 sec Avail.MCT = 1 secondC/O = 1 hourREJ = 3%U/T = 85%27,600 sec. avail.EPE = 2 weeksStamp200 tWeld1OCT = 46 secD/R = 46 secC/O = 10 minREJ = 5%U/T = 80%2 Shifts27,600 sec. Avail.1x dailySub-Assembly1Assembly1MRP18,400 pcs/mo -12,000 “L”-6,400 “R”Tray = 20 pcs2 ShiftsHighland ManufacturingSheet Metal HousingsCurrent State(Date)Daily ShipScheduleWeekly ScheduleTT = 60 sec.ManchesterAvenue6-weekForecastWeeklyfaxProductionControlMRP90/60/30 dayForecastsDailyOrder5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days1 sec. 39 sec. 46 sec. 62 sec. 40 sec.Lead Time= 23.6 daysProcess Time= 188 sec1.客户需求时间为何？SR47 ICoils5 daysI4600 L2400 RI1100 L600 ROCT = 62 secD/R = 62 secC/O = 0REJ = 6%U/T =100%2 Shifts27, 600 sec. Avail.OCT = 40 secD/R = 40 secC/O = 0REJ = 7%U/T = 100%2 Shifts27,600 sec. Avail.ShippingStagingIII1600 L850 R1200 L640 R2700 L1440 RFerrousMetals Co.500 ft coilsTues &ThursMachine1OCT= 39 secD/R = 39 secC/O = 10 minREJ = 4%U/T= 100%2 Shifts27, 600 sec Avail.MCT = 1 secondC/O = 1 hourREJ = 3%U/T = 85%27,600 sec. avail.EPE = 2 weeksStamp200 tWeld1OCT = 46 secD/R = 46 secC/O = 10 minREJ = 5%U/T = 80%2 Shifts27,600 sec. Avail.1x dailySub-Assembly1Assembly1MRP18,400 pcs/mo -12,000 “L”-6,400 “R”Tray = 20 pcs2 ShiftsHighland ManufacturingSheet Metal HousingsCurrent State(Date)Daily ShipScheduleWeekly ScheduleTT = 60 sec.ManchesterAvenue6-weekForecastWeeklyfaxProductionControlMRP90/60/30 dayForecastsDailyOrder5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days1 sec. 39 sec. 46 sec. 62 sec. 40 sec.Lead Time= 23.6 daysProcess Time= 188 sec2. 你将如何满足客户定单你将如何满足客户定单?你是依成品超市生产你是依成品超市生产, 还是依客户定单生产还是依客户定单生产?SR48 0s39s46s62s40sTakt time60 secondsStamp Machine Weld Sub-assy Assy(auto-feed)3. 那里可以执行一件流？在冲压过程？No – why not?不行-为何不行？49 ICoils5 daysI4600 L2400 RI1100 L600 ROCT = 62 secD/R = 62 secC/O = 0REJ = 6%U/T =100%2 Shifts27, 600 sec. Avail.OCT = 40 secD/R = 40 secC/O = 0REJ = 7%U/T = 100%2 Shifts27,600 sec. Avail.ShippingStagingIII1600 L850 R1200 L640 R2700 L1440 RFerrousMetals Co.500 ft coilsTues &ThursMachine1OCT= 39 secD/R = 39 secC/O = 10 minREJ = 4%U/T= 100%2 Shifts27, 600 sec Avail.MCT = 1 secondC/O = 1 hourREJ = 3%U/T = 85%27,600 sec. avail.EPE = 2 weeksStamp200 tWeld1OCT = 46 secD/R = 46 secC/O = 10 minREJ = 5%U/T = 80%2 Shifts27,600 sec. Avail.1x dailySub-Assembly1Assembly1MRP18,400 pcs/mo -12,000 “L”-6,400 “R”Tray = 20 pcs2 ShiftsHighland ManufacturingSheet Metal HousingsCurrent State(Date)Daily ShipScheduleWeekly ScheduleTT = 60 sec.ManchesterAvenue6-weekForecastWeeklyfaxProductionControlMRP90/60/30 dayForecastsDailyOrder5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days1 sec. 39 sec. 46 sec. 62 sec. 40 sec.Lead Time= 23.6 daysProcess Time= 188 sec4. 引导程序在那里？SR50 ICoils5 daysI4600 L2400 RI1100 L600 ROCT = 62 secD/R = 62 secC/O = 0REJ = 6%U/T =100%2 Shifts27, 600 sec. Avail.OCT = 40 secD/R = 40 secC/O = 0REJ = 7%U/T = 100%2 Shifts27,600 sec. Avail.ShippingStagingIII1600 L850 R1200 L640 R2700 L1440 RFerrousMetals Co.500 ft coilsTues &ThursMachine1OCT= 39 secD/R = 39 secC/O = 10 minREJ = 4%U/T= 100%2 Shifts27, 600 sec Avail.MCT = 1 secondC/O = 1 hourREJ = 3%U/T = 85%27,600 sec. avail.EPE = 2 weeksStamp200 tWeld1OCT = 46 secD/R = 46 secC/O = 10 minREJ = 5%U/T = 80%2 Shifts27,600 sec. Avail.1x dailySub-Assembly1Assembly1MRP18,400 pcs/mo -12,000 “L”-6,400 “R”Tray = 20 pcs2 ShiftsHighland ManufacturingSheet Metal HousingsCurrent State(Date)Daily ShipScheduleWeekly ScheduleTT = 60 sec.ManchesterAvenue6-weekForecastWeeklyfaxProductionControlMRP90/60/30 dayForecastsDailyOrder5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days1 sec. 39 sec. 46 sec. 62 sec. 40 sec.Lead Time= 23.6 daysProcess Time= 188 sec5. 不连贯程序可以使用何種拉引系统？这个超市可以消除什么？SR51 0s39s46s62s40sTakt time60 secondsStamp Machine Weld Sub-assy Assy(auto-feed)还有别的地方可执行一件流吗？是车削和焊接過程吗？Yes!就是这里52 ICoils5 daysI4600 L2400 RI1100 L600 ROCT = 62 secD/R = 62 secC/O = 0REJ = 6%U/T =100%2 Shifts27, 600 sec. Avail.OCT = 40 secD/R = 40 secC/O = 0REJ = 7%U/T = 100%2 Shifts27,600 sec. Avail.ShippingStagingIII1600 L850 R1200 L640 R2700 L1440 RFerrousMetals Co.500 ft coilsTues &ThursMachine1OCT= 39 secD/R = 39 secC/O = 10 minREJ = 4%U/T= 100%2 Shifts27, 600 sec Avail.MCT = 1 secondC/O = 1 hourREJ = 3%U/T = 85%27,600 sec. avail.EPE = 2 weeksStamp200 tWeld1OCT = 46 secD/R = 46 secC/O = 10 minREJ = 5%U/T = 80%2 Shifts27,600 sec. Avail.1x dailySub-Assembly1Assembly1MRP18,400 pcs/mo -12,000 “L”-6,400 “R”Tray = 20 pcs2 ShiftsHighland ManufacturingSheet Metal HousingsCurrent State(Date)Daily ShipScheduleWeekly ScheduleTT = 60 sec.ManchesterAvenue6-weekForecastWeeklyfaxProductionControlMRP90/60/30 dayForecastsDailyOrder5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days1 sec. 39 sec. 46 sec. 62 sec. 40 sec.Lead Time= 23.6 daysProcess Time= 188 sec还有别的地方可执行一件吗？这里用一件流，什么会消失？VRKSR53 0s39s46s62s40sTakt time60 secondsStamp Machine Weld Sub-assy Assy(auto-feed)还有别的地方可执行一件流吗？是组裝過程吗？Yes!正是54 ICoils5 daysI4600 L2400 RI1100 L600 ROCT = 62 secD/R = 62 secC/O = 0REJ = 6%U/T =100%2 Shifts27, 600 sec. Avail.OCT = 40 secD/R = 40 secC/O = 0REJ = 7%U/T = 100%2 Shifts27,600 sec. Avail.ShippingStagingIII1600 L850 R1200 L640 R2700 L1440 RFerrousMetals Co.500 ft coilsTues &ThursMachine1OCT= 39 secD/R = 39 secC/O = 10 minREJ = 4%U/T= 100%2 Shifts27, 600 sec Avail.MCT = 1 secondC/O = 1 hourREJ = 3%U/T = 85%27,600 sec. avail.EPE = 2 weeksStamp200 tWeld1OCT = 46 secD/R = 46 secC/O = 10 minREJ = 5%U/T = 80%2 Shifts27,600 sec. Avail.1x dailySub-Assembly1Assembly1MRP18,400 pcs/mo -12,000 “L”-6,400 “R”Tray = 20 pcs2 ShiftsHighland ManufacturingSheet Metal HousingsCurrent State(Date)Daily ShipScheduleWeekly ScheduleTT = 60 sec.ManchesterAvenue6-weekForecastWeeklyfaxProductionControlMRP90/60/30 dayForecastsDailyOrder5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days 1 sec. 39 sec. 46 sec. 62 sec. 40 sec.Lead Time= 23.6 daysProcess Time= 188 sec还有别的地方可执行一件流吗？是组裝過程吗？这里用一件流，什么会消失？VRKSR55 187 seconds work =3.1 operators60 seconds TAKT = 4 operators = 3 operators (target)还有别的地方可执行一件流吗？看看操作员周期时间？5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days 1 sec. 39 sec. 46 sec. 62 sec. 40 sec.MCTOCTOCTOCTOCT完成一件的总人工时间是多久？39 + 46 + 62 + 40 = 187 seconds但是顾客每60秒需要一件第四位操作员做其它有意义的工作比较重要56 Takt time60 secondsMachine WeldWeldSub-AssemblyAssembly60 secs. 60 secs. 54 secs.58 x 3 = 174 seconds未来状态的操作员负荷表未来状态的操作员负荷表57 ICoils5 daysI4600 L2400 RI1100 L600 ROCT = 62 secD/R = 62 secC/O = 0REJ = 6%U/T =100%2 Shifts27, 600 sec. Avail.OCT = 40 secD/R = 40 secC/O = 0REJ = 7%U/T = 100%2 Shifts27,600 sec. Avail.ShippingStagingIII1600 L850 R1200 L640 R2700 L1440 RFerrousMetals Co.500 ft coilsTues &ThursMachine1OCT= 39 secD/R = 39 secC/O = 10 minREJ = 4%U/T= 100%2 Shifts27, 600 sec Avail.MCT = 1 secondC/O = 1 hourREJ = 3%U/T = 85%27,600 sec. avail.EPE = 2 weeksStamp200 tWeld1OCT = 46 secD/R = 46 secC/O = 10 minREJ = 5%U/T = 80%2 Shifts27,600 sec. Avail.1x dailySub-Assembly1Assembly1MRP18,400 pcs/mo -12,000 “L”-6,400 “R”Tray = 20 pcs2 ShiftsHighland ManufacturingSheet Metal HousingsCurrent State(Date)Daily ShipScheduleWeekly ScheduleTT = 60 sec.ManchesterAvenue6-weekForecastWeeklyfaxProductionControlMRP90/60/30 dayForecastsDailyOrder5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days 1 sec. 39 sec. 46 sec. 62 sec. 40 sec.Lead Time= 23.6 daysProcess Time= 188 sec看过操作员周期时间后，还有别的地方可执行一件流吗？这里用一件流，什么会消失？VRKSTD WK38% Prod. ImpSMED<10 min.SR58 StampShippingHousing Cell1xdailyFerrousMetals Co.Tues &Thurs18,400 pcs/mo-12,000 “L”- 6,400 “R”.Tray = 20 pcs2 shiftsOCT = 174 sec.D/R = 60 sec.MCT = 75 sec.C/O = 57 secs.Rej = 1%U/T = 80%MCT = 1 sec.C/O = 1 hourRej = 1%U/T = 85%500 ft coils2 daysTakt = 460 min. / 460 pcs. = 60 secPitch = 60 sec. X 20 pcs. = 20minHighland ManufacturingHousingsFuture State(Date)ManchesterAvenueDaily ShipSchedule920 pcs/dayICoils5 daysVRK UT>95%STD WK38% Prod. ImpSMED<10 min6-weekForecastWeeklyfaxProductionControlMRP90/60/30 dayForecastsDailyOrder这是到目前为止，未来图看起来的样子SR59 StampShippingHousing Cell1xdailyFerrousMetals Co.Tues &Thurs18,400 pcs/mo-12,000 “L”- 6,400 “R”.Tray = 20 pcs2 shiftsOCT = 174 sec.D/R = 58 sec.MCT = 75 sec.C/O = 57 secs.Rej = 1%U/T = 80%MCT = 1 sec.C/O = 1 hourRej = 1%U/T = 85%500 ft coils2 daysTakt = 460 min. / 460 pcs. = 60 secPitch = 60 sec. X 20 pcs. = 20minHighland ManufacturingHousingsFuture State(Date)ManchesterAvenueDaily ShipSchedule920 pcs/dayICoils5 daysVRK UT>95%STD WK38% Prod. ImpSMED<10 min6-weekForecastWeeklyfaxProductionControlMRP90/60/30 dayForecastsDailyOrder605. 中断的程序之间使用何种拉引系统？试试冲压过程的拉引SR60 StampShippingHousing Cell1xdailyFerrousMetals Co.Tues &Thurs18,400 pcs/mo-12,000 “L”- 6,400 “R”.Tray = 20 pcs2 shiftsOCT = 174 sec.D/R = 58 sec.MCT = 75 sec.C/O = 57 secs.Rej = 1%U/T = 80%MCT = 1 sec.C/O = 1 hourRej = 1%U/T = 85%500 ft coils2 daysTakt = 460 min. / 460 pcs. = 60 secPitch = 60 sec. X 20 pcs. = 20minHighland ManufacturingHousingsFuture State(Date)ManchesterAvenueDaily ShipSchedule920 pcs/dayICoils5 daysVRK UT>95%STD WK38% Prod. ImpSMED<10 min6-weekForecastWeeklyfaxProductionControlMRP90/60/30 dayForecastsDailyOrder60若运输看板已被提取，冲压工作的生产看板将会如何？60SR61 StampShippingHousing Cell1xdailyFerrousMetals Co.Tues &Thurs18,400 pcs/mo-12,000 “L”- 6,400 “R”.Tray = 20 pcs2 shiftsOCT = 174 sec.D/R = 58 sec.MCT = 75 sec.C/O = 57 secs.Rej = 1%U/T = 80%MCT = 1 sec.C/O = 1 hour, = 6minRej = 1%U/T = 85%500 ft coils2 daysTakt = 460 min. / 460 pcs. = 60 secPitch = 60 sec. X 20 pcs. = 20minHighland ManufacturingHousingsFuture State(Date)ManchesterAvenueDaily ShipSchedule920 pcs/dayICoils5 daysVRK UT>95%STD WK38% Prod. ImpSMED<10 min6-weekForecastWeeklyfaxProductionControlMRP90/60/30 dayForecastsDailyOrder60batch1.5 days为了平稳化和混合生产，在引导点该如何做生产排程？46 trays20stageSRSMED<10 min62 StampShippingHousing Cell1xdailyFerrousMetals Co.Tues &Thurs18,400 pcs/mo-12,000 “L”- 6,400 “R”.Tray = 20 pcs2 shiftsOCT = 174 sec.D/R = 58 sec.MCT = 75 sec.C/O = 57 secs.Rej = 1%U/T = 80%MCT = 1 sec.C/O = 1 hourRej = 1%U/T = 85%500 ft coils2 daysTakt = 460 min. / 460 pcs. = 60 secPitch = 60 sec. X 20 pcs. = 20minHighland ManufacturingHousingsFuture State(Date)ManchesterAvenueDaily ShipSchedule920 pcs/dayICoils5 daysVRK UT>95%STD WK38% Prod. ImpSMED<10 min6-weekForecastWeeklyfaxProductionControlMRP90/60/30 dayForecastsDailyOrder60batch1.5 days为了平稳化和混合生产，在引导点该如何做生产排程？46 traysstage34200X0X2012RLLRLL…pitch = 20 min.SR63 StampShippingHousing Cell1xdailyFerrousMetals Co.18,400 pcs/mo-12,000 “L”- 6,400 “R”.Tray = 20 pcs2 shiftsOCT = 174 sec.D/R = 58 sec.MCT = 75 sec.C/O = 57 secs.Rej = 1%U/T = 80%MCT = 1 sec.C/O = 1 hourRej = 1%U/T = 85%500 ft coils2 daysTakt = 460 min. / 460 pcs. = 60 secPitch = 60 sec. X 20 pcs. = 20minHighland ManufacturingHousingsFuture State(Date)ManchesterAvenueDaily ShipSchedule920 pcs/dayVRK UT>95%STD WK38% Prod. ImpSMED<10 min6-weekForecastWeeklyfaxProductionControlMRP90/60/30 dayForecastsDailyOrder60batch1.5 days逐一检讨什么地方可以再建立一个超市？46 traysstage0X0X20123420RLLRLL…pitch = 20 min.Daily1.5 daysCoilDailyICoils5 daysSR64 StampShippingHousing Cell1xdailyFerrousMetals Co.18,400 pcs/mo-12,000 “L”- 6,400 “R”.Tray = 20 pcs2 shiftsOCT = 174 sec.D/R = 58 sec.MCT = 75 sec.C/O = 57 secs.Rej = 1%U/T = 80%MCT = 1 sec.C/O = 1 hourRej = 1%U/T = 85%500 ft coils2 daysTakt = 460 min. / 460 pcs. = 60 secPitch = 60 sec. X 20 pcs. = 20minHighland ManufacturingHousingsFuture State(Date)ManchesterAvenueDaily ShipSchedule920 pcs/dayVRK UT>95%STD WK38% Prod. ImpSMED<10 min6-weekForecastWeeklyfaxProductionControlMRP90/60/30 dayForecastsDailyOrder60batch1.5 days46 traysstage0X0X20123420RLLRLL…pitch = 20 min.Daily1.5 daysCoilDaily不再需要用物料需求计划来管制生产1.5 days1 sec.174 sec2 days1.5 daysLead TimeProcessTime= 5 days= 175 sec.SR？？65 StampHousing CellManchesterAvenue1xdailyShippingStageFerrousMetals Co.Production Control6- weekForecastDailyOrderDaily(milk run)Coils1.5 days20batch60COIL2020200X0XDaily Ship Schedule90/60/30 dayForecastsDailyOrder1.5 days1 sec.1.5 days174 sec2 daysLead TimeProcessTime= 5 days= 175 sec.SMEDVRKU/T >95%Highland Future State MapMRP4046 Trays1.5 days2 daysRLLRLL…pitch = 20 min.18,400 pcs/mo-12,000 “L”- 6,400 “R”.Tray = 20 pcs2 shifts920 pcs/dayTakt = 460 min / 460 pcs = 60 sec .Pitch = 60 sec x 20 pcs = 20 min1234OCT = 174 sec.D/R = 58 sec.MCT = 75 sec.C/O = 57 secs.Rej = 1%U/T = 80%.MCT = 1 sec.C/O = 1 hourRej = 1%U/T = 85%STD WK38% Prod. ImpHighland ManufacturingHousingsFuture State(Date)DMPSMEDDMPDMP7. 需要何种改善活动、项目和LEAN工具来达成未来状态？SR66 StampHousing CellManchesterAvenue1xdailyShippingStagingFerrousMetals Co.Production Control6- weekForecastDailyOrderDaily(milk run)Coils1.5 days20batch60COIL2020200X0XDaily Ship Schedule90/60/30 dayForecastsDailyOrder1.5 days1 sec.1.5 days174 sec2 daysLead TimeProcessTime= 4.5 days= 175 sec.SMEDVRKU/T >95%Highland Future State MapMRP4046 Trays1.5 days2 daysRLLRLL…pitch = 20 min.18,400 pcs/mo-12,000 “L”- 6,400 “R”.Tray = 20 pcs2 shifts920 pcs/dayTakt = 460 min = 60 sec 460 pcs.Pitch = 60 sec x 20 pcs = 20 min1234OCT = 174 sec.D/R = 58 sec.MCT = 75 sec.C/O = 57 secs.Rej = 1%U/T = 80%MCT = 1 sec.C/O = 1 hourRej = 1%U/T = 85%STD WK38% Prod. ImpHighland ManufacturingHousingsFuture State(Date)DMPSMEDDMPDMPSupplier CycleStamp CyclePacemaker CycleSR67 8. 改善活动和项目的优先级为何？?Action行动Team Leader小组领导员When完成日期DMP event to implement the finished good supermarket.DMP改善活动 ─ 完成成品超市Doug3/14Housing Cell SMED to allow production to takt time and mix leveling at the housing cell.外罩细胞的快速换模改善活动 ─ 使外罩细胞的生产符合客户需求时间并平稳混合生产Sandy3/21Spot Welder VRK to determine why the downtime is occurring, and what can be done to eliminate the root causes. 点焊工作的降低变异改善活动 ─ 找出停机的原因和解决方法，以消除根本原因Bill4/10Standard work event to implement the new housing cell.标准工作改善活动 ─ 完成新的外罩细胞Doug4/10DMP event to implement pull at stamping and for the supply of coils. 压字的DMP改善活动 ─ 完成拉引系统，同时解决钢料的供应Sue5/1SMED kaizen event at stamping to reduce the changeover time to less than ten minutes压字的快速换模改善活动 ─ 缩短换模时间至十分钟以内.Bill5/1DMP to implement heijunka at the housing cell.外罩细胞的DMP改善活动 ─ 推行平准化生产Sandy5/1568 谢谢 谢谢69 。