ValueStreamMapWCLEOfficeTrainingMaterialValueStreamMapping(VSM)WhatisaValueStream?2ValueStreamisalltheActivities(bothVAandNVA)requiredtobringaproductthroughfromrawmaterialstothehandsoftheCustomerValueStreamMapisastandardMethodforhighlevelprocessMappingIIMoldingTrimAssemblyWhatisaValueStream?3Helpstovisualize/understand/highlight

Material&InformationFlowHelpstoseeWasteandImproveopportunitiesAllowseveryonetogainacommonunderstandingoftheCurrentstate(AS-IS)andtheFuturevision(TO-BE)What’sinItforMe?4StepsforValueStreamMapping4Tues.&Fri.PC&LWeeklyOrderMRPMSSWeeklyOrder#times/daySteelSupplierSteelPin#

pcs#daysorshiftsIIIIStampingDowntimeChangeoverTime=4hr2ShiftsTAKT=2Presses

CycleTime=ChangeOverWeldingLayoutScrap/ReworkDowntime=20%Uptime#OperatorsCycleTime=WeeklyBuildScheduleDailyShipSchedule6WeekRollingForecast6WeekRollingForecastFinishedGoodsOvertime=#Shifts=AssemblyDT,ScrapReworkWIP=CycleTime=TAKT=

ChangeoverTime=Layout=10%Scrap?days?days?days?days?days?days?daysInventoryTimeProcessingTimeTPc/t=?TAKT=

WIP=

WIP=

WIP=Xpcs/monthStd.PackQty.#shiftsCustomerCurrentVSM

FinishedGoodsAssemblyLayoutWeldingRolling6-wkForecastWeeklyOrder6x/DayPC&L6-wkforecastDailyLevelBox

DA1

DA2

DA3C/OTime=CT=TAKTTime3ShiftsDT=Scrap=Stamping0Overtime2ShiftsMaxSize#MaterialHandlersC/OTime=CT=TAKTTime3ShiftsDT=Scrap/Rework=C/OTime=CT=TAKTTime3ShiftsDT=Scrap/Rework=SmallLot#OperatorsCustomerX

pcs/monthStdPackQty#ShiftsWIP=WIP=WIP=SteelSupplierInv.TimeProc.TimeTPc/t=??days?days?days?days?days?days?daysFutureVSMPlanandfollowupWHEREWeAREWHERETOGOHOWTOGO5Level1ValueStreamMapping-VSM(Strategicdirection)Level2Functionalmapping(Processre-engineering)Level3Flowdiagramformaterialsandinformation(Improvementofworkmethods)Level1–ValueStreamMappingLeanmakessense…精益能夠做到Processviewedbyyou你所見到的流程Processinreality實際執(zhí)行的流程Targetedprocess精益流程Software?SMART!!CURRENTLCMFLOWNormalflowfromcustomertocustomerLeadtimebetweenOIanddeliveryreadytobeshipped:from8to4weeksOTIF:85%ofeverylineshipped8Selectproduct/processfamilyDrawcurrentstateCreatefuturestateImplementactionplanStepsforValueStreamMappingRepeattheProcessSelectpriorityprocessesIdentifywastesandimprovementopportunitiesDrawideasdirectlyonVSMDrawprocessusingpencil/eraserCollectallpossibledataonshopfloorTIPSSTEPSDevelop&executeakaizenplanReviewplanregularlytoachievefuturestateContinuousimprovement…9Selectproduct/processfamilyDrawcurrentstateCreatefuturestateDevelop/executeimproveStepsforValueStreamMappingRepeattheProcess10#1SelectProductFamily–PQPRexamplePROCESSMACHINESTocreateaproductfamilymatrix,listyourproductsandtheprocessstepsworkingbackwardsfromthecustomeralongthetop.LookforcommonprocessstepsthatapplytoseveralproductsTheseproductscanthenbegroupedintofamilies.11Selectproduct/processfamilyDrawcurrentstateCreatefuturestateImplementactionplanStepsforValueStreamMappingRepeattheProcess12#2DrawCurrentStateSomehints:Useactual,observeddataBeginatendpoint&proceedinreverseflowWalktheentireprocessfirstbeforerecordingdataEveryoneontheteamshouldcreatetheirownmapUsepencilandpaper13#2DrawCurrentState:SampleSymbolsMachiningProcessBoxDataBoxIInventory1OperatorManualInformationElectronicInformationC/T=36SecSetUpTime7MinUptime86%BatchSize50InspectionPointWithdrawalKanbanPushArrowCustomers/SuppliersToCustomerProductionKanbanSupermarketTruckShipmentFutureStateImprovement“GoSee”SchedulingDailyScheduleSchedule14MANUFACTURINGCycleTime(machine,manual)LeadTimeQueueTimeTransportationTimeChangeOvertime(c/o)Availability(uptime)Batch(lot)SizeQuality%(scraprate,reworks,..)n#OperatorsPROCUREMENTLTfromPartRequesttoPurchaseOrdern#ofPR/POtobeprocessed(queue)Quality%=POprocessedwithouterrorsn#resourcedusedDESIGNLTtoBOManddwgemissionn#oforderstobeprocessed(queue)Quality%ofcorrectBOM/dwg1°timeDelivery%ofBOManddrawingontimevs.totaln#resourcedusedper#ofshiftsn#drawingchanges#2CurrentState–ExampleofdatatocollectNotsonecessarytobesoprecise,butgoodreferenceforjudgment!15Cu糖st煤om滑er塑o垂r擦Su璃pp找li屋erPr浮oc奔es拆s貞(e鼠nd齊s壩wh亞en夏t倆he行f恢lo遭w耗st模op路s)Us炭e聚th渡e敞fo煉ll耐ow韻in黑g率fo李rm蝕s:#2頂C間ur壘re境nt多S勉ta戒te則–悶P民RO截CE息SS毒&背A暗CT田IV題IT勒Y輸IN嫌VO逼LV蜂ED16In你ve摩nt聞or傳y,活W蕉IPFl莖ow地o額f莫ma輪te迷ri惕al藥(識pr蛇od壞uc張ti踏on欠p遙us恨h始fl賄ow染)Fl始ow厭o雹f桂fi嘴ni融sh鬼ed魄g緊oo戴ds遞o椒r券ra介w英ma為te廁ri冊al恒sMe所an設(shè)s蘭of并t困ra屋ns萄po緞rt驅(qū)at只io鍵nUs另e勸th座e猛fo尺ll蠢ow五in既g掉fo元rm伯s:#2粱C度ur觸re景nt冤S暮ta厭te異–童M購AT疾ER廊IA乏L切FL縣OW17wk吸lyor茂de搜r#2凱C羽UR證RE緣瑞NT虎S卵TA鑰TE騙–朗I掉nf尋or烈ma敏ti漆on賣f作lo泄wManualInformationUsethefollowingforms:ElectronicInformation18wklyorder#2繭C格UR欣RE銜NT帽S迫TA沖TE質(zhì)–郵D柜at概a夠bo慈x19Ma咱ch旗in許ex2C/佩T黨54漸s席ecC/馳O焦34倍m慶in2偽sh證if粱tsUT欄9曬0%ProcessdescriptionNumberofoperatorson1shiftCycletime:totaltimetocomplete1unitChangeovertime:totaltimetochangefrompartAtopartBNumberofshiftsUptime:O.E.E.ofselectedprocess#2獲C虛UR冤RE船NT材S煉TA倒TE晴–猛D排at盆a震bo耳x20wklyorder#2巾C特UR念RE項NT滑S灶TA誦TE徹–我T半im束el萄in避e齒of講P敲ro嶺du參ct始io軟nle榨ad挨ti夕me21#2希C習(xí)UR準RE東NT歐S餃TA仁TE瞞–醋E邀xa查mp霸le肚sBy總h絮an朱d22Se役le葵ct綢p碎ro六du修ct左/p哭r(nóng)o診ce毛ss斯f咐am陪il渣yDr獲aw輛c昨ur濟re浸nt掛s暴ta枝teCr裁ea榮te也f際ut炭ur侵e繞st糞at叮eIm國pl仆em棕en揮t苦ac塌ti冬on錦p戴la漆nSt床ep橋s遙fo類r啞Va紀lu雄e評St紹re駛am容M屈ap識pi蠅ngRe藏pe埋at大t壩he領(lǐng)P味ro府ce錘ss23Is助t獎he意b耽as辨is止o技f避a栗pl享an但t敗ow烏ar稠ds熄a獵L租ea侮n箏Pr迫od糾uc夫ti仿on吐S級ys荒te醒mAl莫lo關(guān)ws兔f毒ul蓋l稻pa張rt尸ic態(tài)ip畢at鎮(zhèn)io鈴n卡an料d吊bu突y-怠in芬o虹f燭th醒e涌te吼am背i策n超de匙ve間lo躺pi觸ng糞t喇he敵f俯ut暑ur曾e擾vi壇si峽on濟o汁f逝th山e街bu赴si很ne輕ssSu腿mm蛾ar省iz綁e效im鎮(zhèn)pr勿ov猶em侵en意t紡ne調(diào)ed樸sIs歇a賄s薯tr撿ea團m場of蚊v凈al飼ue畝-a裙dd則in貞g蘆fl妄ow癢l英in筆ke貓d渠to思t渡he崖c取us鏡to貸me色r慶by株p嶼ul胖l征or售c頸on錄ti超nu鎖ou例s淘fl乒ow#3采F鄙UT后UR裁E外ST麥AT槽E歡–淺Pu銀rp遭os只e24Do棋es將t藝he舍s村te蘿p續(xù)br光in飲gva腸lu圈eto跨t激he古c則us陪to禍me呆r?if微n吹ot密,祥an租d庫if踐p料os大si枯bl赤e微tr道y厘toel狡im交in濫at酸e丘st膠ep#3瞞F兩UT艱UR改E繞ST俊AT隱E殺–挖Hi忘nt尺s閉to效d頂ra判w傳th齡e輝vi滲si賄onIs扛t逢he愚s開te遭pca芳pa駕bl屑e(s昌am鏟e省re數(shù)su駝lt抽e業(yè)ve熔ry殲t未im決e)鉆?if大n白ot肯,奇lo虛ok己t疏heQu濱al統(tǒng)it韻y館pr汪oc淘es飾s,掏r雹ed骨uc再e喉va推ri鹽an戒ce樣,界…Ar胞e唉pr超oc土es貴s秩st便ep真sli殺nk灑ed次b貧y樓pu委ll,好do可es傘t鍋he字p爭ro避du側(cè)ct擔f枕lo修w繡to聞t逆he暈n綱ex貸t?刺i布f辱no倚t秤im呆pl飛em面en鳳tJu網(wǎng)st奮I軌n漫Ti紅me飯(鴉fr府omBat桂chtoFl性ow,U-笑ce孕l(wèi)l者,Ta升kt-t卷im輸e,鞠S撿td徐w榆or悅k)Wh承er毅e合yo桐u遇ca翁nn光otFl棟ow(c稱om踏bi色ne卸d拉e-男co仔up猴le給d鉆pr查oc棄es蒙s)察g只o劫fr睬omPu妻shtoPu財llto精r永ed繁uc辰e撤in婦ve春nt漢or碎y端us管in塑gka慘nb換an,碌su欺pe嚷rm貌ar純ke汗tBat呢ch25Is輝t膀he罵s阻te云pav倘ai黎la棵bl買e:ca溫n抵it線p禽ro技du日ce乘t謎he呼d抽es糖ir您edou預(yù)tp正ut端&q到ua旬li物ty,發(fā)ev稿er傾y扎ti豆me常?特if辨n湯ot牢,味im雞pl已em住en源tTo旬ta射l悼Pr挺od帖uc招ti稈ve鞠M占ai哀nt付en敬an缸ce#3深F材UT旱UR腥E悠ST寸AT叼E罰–鉤Hi鴨nt憂s鋪to晚d鈴ra威w串th戒e狠vi畝si殖onIs缸t掠he皇s錫te座pad美eq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