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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 pr
2、ocess 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 for Me?,
3、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 methods),Leve
4、l 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%of every line sh
5、ipped,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 Collect all po
6、ssible 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 Process,Page 11,#1 Se
7、lect 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 families.,Page 12,Select
8、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 before recording data Every
9、one 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 Customer,ProductionKanban,S
10、upermarket,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#Operators,PROCUREMENTLT from Part
11、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 n#resourced used per#of shiftsn#drawing chang
12、es,#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,Page 17,Inventory,WIPFlow of material(production push fl
13、ow)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 min,2 shifts,UT 90%,#2 CURRENT STATE Data box,Page 21,
14、#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 24,Is the basis of a plan towards a Lean Production Sys
15、tem 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,Does the step bring value to the customer?if not,and if
16、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
17、 work),Where you cannot Flow(combine de-coupled process)go from Push to Pull to reduce inventory using kanban,supermarket,Batch,Page 26,Is the step available:can it produce the desired output&quality,every time?if not,implement Total Productive Maintenance,#3 FUTURE STATE Hints to draw the vision,Is
18、 the step adequate:is the capacity to low(product is waiting for the step)or to high(big machines)reduce cycle,increase capacity,review bottleneck exploitation and work release,Is the step flexible:can it be changed over quickly to allow small lot/single piece production?if not,implement Single Minu
19、te Exchange of Dies(SMED),Page 27,X,X,X,X,#3 FUTURE STATE Highlight improve opportunities,Page 28,#3 FUTURE STATE Plot the vision,U-cell,Kanban&Smkt,SMED,Flow,Product Leveling,Fifo line,Std Work,Page 29,Select product/process family,Draw current state,Create future state,Implement action plan,Steps
20、for Value Stream Mapping,Repeat the Process,Page 30,Kaizen Plan&Newspaper,Plan,Execute,Verify and Control improvement steps,Page 31,Select product/process family,Draw current state,Create future state,Develop/execute improve,Steps for Value Stream Mapping,Repeat the Process,Page 32,When the Future S
21、tate becomes a reality,it becomes our current state We are only at the beginning of our continuous improvement journey Strive for PERFECTION!,Is it over?,Page 33,What are the two main flows represented in a Value Stream MapWhat is the purpose of a Value Stream Mapping?Which are the steps of the VSM?Name three questions that one will ask about each process element of a VSM and the corresponding LEAN technique that can be applied to possibly address it.,Lesson learnt,Page 34,Thank you!,
