精益生产价值流图(英文版)

1精益生产价值流图(英文版)WhatisLean?Leanisathatfocuseson:CreatingvaluefortheCustomerEliminatingWasteContinuousincrementalimprovementThinkingProcess2ENERGIZERSCHICK-HIGHLYCONFIDENTIAL-RESTRICTEDFORINTERNALUSEONLYWhatisaValueStream?“Alloftheactions,valueornonvalueaddedthatarerequiredtobringaproductfromconcepttolaunchorfromrawmaterialordertodelivery...”From“LeanLexicon”3ENERGIZERSCHICK-HIGHLYCONFIDENTIAL-RESTRICTEDFORINTERNALUSEONLYOrderFulfillmentValueStreamIdeally,we’dwantthematerials,informationandcashtoflowsmoothly(withoutinterruption)andasquicklyaspossiblethroughthisstream.SalesOrderReceiptRMOrder&ReceiptManufacturingPackagingDistributionDelivery/Service4ENERGIZERSCHICK-HIGHLYCONFIDENTIAL-RESTRICTEDFORINTERNALUSEONLYLeanElementsValueStream=ValueProvidingProcessesPullPerfectionFlowValue5ENERGIZERSCHICK-HIGHLYCONFIDENTIAL-RESTRICTEDFORINTERNALUSEONLYValue“WhatisthewillingtoPayfor?”3TypesofCustomers:Theexternalend-userorpayingcustomerThedownstreamcustomerofanyinternalupstreamprocess.Yourcompanyasthecustomerofexternalsuppliers.Customer6ENERGIZERSCHICK-HIGHLYCONFIDENTIAL-RESTRICTEDFORINTERNALUSEONLYFlowIdealflow=1pieceatatimeRatedeterminedbycustomerdemand-TakttimeWorkbalancedforeachpersonormachineTraveldistanceformaterials&peopleminimizedStandardWorkutilizedFlowwhatyoucan…Pullwhatyoucan’t…Requiresthatallstepsintheprocessbe:Capable=RighteverytimeAvailable=AlwaysabletorunAdequate=Capacitytoavoidbottlenecks7ENERGIZERSCHICK-HIGHLYCONFIDENTIAL-RESTRICTEDFORINTERNALUSEONLYPhasesofLeanJourneyPhase1-Identify/MapValueStreamsPhase2-PrioritizeopportunitiesPhase3-UtilizeLeantoolstoeliminatewastePhase4-ControltheflowPhase5-LeanmetricsPhase6-Re-evaluateValueStreamsandbeginagain8ENERGIZERSCHICK-HIGHLYCONFIDENTIAL-RESTRICTEDFORINTERNALUSEONLYItAllstartswithWasteIdentificationIdentifyallformsofWastethroughoutourentireValueStreambefore:ReducingthewasteorEliminatingthewasteThiswillenableustoprioritizeoureffortsandfocusonthehighpotentialeventsfirst.9ENERGIZERSCHICK-HIGHLYCONFIDENTIAL-RESTRICTEDFORINTERNALUSEONLY8WastesOverproductionInventoryWaitingTransportingUnnecessaryprocessingUnnecessarymotionDefectsUnderutilizationofpeople10ENERGIZERSCHICK-HIGHLYCONFIDENTIAL-RESTRICTEDFORINTERNALUSEONLYOver-ProductionProducingmorethanwhatthecustomerreallywants.WaystoOvercome:ReducesetuptimesSynchronizetimeandamountofprocessesCreatecompactlayoutsandvisibility11ENERGIZERSCHICK-HIGHLYCONFIDENTIAL-RESTRICTEDFORINTERNALUSEONLYInventoryExcessinventoryrequireshandling,space,$$,people,andpaperwork.WaystoOvercome:SynchronizeworkflowtoreduceaccumulationShortensetuptimeReduceleadtimeCellularlayoutsZeroQualityDefectsReducingallotherwastesreducesthewasteofinventory12ENERGIZERSCHICK-HIGHLYCONFIDENTIAL-RESTRICTEDFORINTERNALUSEONLYWaitingWaitingforupstreamprocessesduetopoorlayout,unbalancedworkloadorequipmentdowntime.WaystoOvercome:SynchronizeworkflowBalanceunevenloadsbyflexibleworkersandequipmentImplementpreventivemaintenancetoeliminatemachinedown-time13ENERGIZERSCHICK-HIGHLYCONFIDENTIAL-RESTRICTEDFORINTERNALUSEONLYTransportationTransportationaddsNovaluetotheproduct.Ratherthanimprovethetransportation:ReduceitEliminateit.WaystoOvercome:Establishlayoutandlocationswhichreducesoreliminatestransportation14ENERGIZERSCHICK-HIGHLYCONFIDENTIAL-RESTRICTEDFORINTERNALUSEONLYUnnecessaryProcessingSamedataenteredinto3differentinformationsystems.(SAP,Access,Excel)Allunnecessary,orNon-ValueAdded,processingstepsshouldbeeliminatedWaystoOvercome:QuestionifprocessisnecessaryatallSimplifyUseStandardWorkReduceHandoffs/approvals15ENERGIZERSCHICK-HIGHLYCONFIDENTIAL-RESTRICTEDFORINTERNALUSEONLYUnnecessaryMotionMotionofpeople,machines,andproductsiswaste.WaystoOvercome:Studymotionandeliminateorreducemotionthroughimprovedlayouts.CellularManufacturingRethinkmaterialstorageJob/TaskCombinations16ENERGIZERSCHICK-HIGHLYCONFIDENTIAL-RESTRICTEDFORINTERNALUSEONLYDefects(Correction)Makingdefectiveproductispure(muda)waste.FocusonpreventingdefectsNotfindingandrepairingdefectsWaystoOvercome:Mistake-prooftopreventdefectsNeverPassdefectsStandardWork17ENERGIZERSCHICK-HIGHLYCONFIDENTIAL-RESTRICTEDFORINTERNALUSEONLYWasteofUnderutilizingPeopleTheeighthwasteisnotfullyutilizingthetimeandtalentsofpeople.Whoarethe“real”experts?andwhatdotheyknow?18ENERGIZERSCHICK-HIGHLYCONFIDENTIAL-RESTRICTEDFORINTERNALUSEONLYPurposeofValueStreamMappingThepurposeofthevaluestreammapistolookatthebigpictureandtodevelopa“future-state”mapbyeliminatingallnon-valueaddedactivitiesandminimizingallnon-value-addedbutrequiredactivities.19ENERGIZERSCHICK-HIGHLYCONFIDENTIAL-RESTRICTEDFORINTERNALUSEONLYBasicCurrentStateMAPPINGTIPS1Cross-functionalTeamcompletesthemapStartatthecustomerendWalktheactualpathwaysofbothmaterialandinformationflow.Drawbyhandinpencil.20ENERGIZERSCHICK-HIGHLYCONFIDENTIAL-RESTRICTEDFORINTERNALUSEONLYValueStreamMappingIconsProcessIcons21ENERGIZERSCHICK-HIGHLYCONFIDENTIAL-RESTRICTEDFORINTERNALUSEONLYValueStreamMappingIconsInformationFlowIcons22ENERGIZERSCHICK-HIGHLYCONFIDENTIAL-RESTRICTEDFORINTERNALUSEONLY23ENERGIZERSCHICK-HIGHLYCONFIDENTIAL-RESTRICTEDFORINTERNALUSEONLYProductionLeadTime=23.5daysValueAddedTime=184SecondsFrom"LearningtoSee"byMikeRotherandJohnShookCurrentStateMap24ENERGIZERSCHICK-HIGHLYCONFIDENTIAL-RESTRICTEDFORINTERNALUSEONLYFutureStateQuestionsHowdowefocusontheLeadtime?UnderstandthetakttimeWhatareaintheprocesstriggersproduction?Willwebuildtoshippingortoasupermarket?Wherecanweusecontinuousflow?WhatitemsorEventsrequireProcessMapsHowdowesimplifyWheredowereducetravel&redundancy?Whatprocessimprovementscanwedo?25ENERGIZERSCHICK-HIGHLYCONFIDENTIAL-RESTRICTEDFORINTERNALUSEONLY•UsethelistoffuturestatequestionsHaveyourcross-functionalgroupbrainstormUtilize“outside”folksandyourselftoquestioneverythingYoucansketchfuturestateideasatthetabletodiscussIfyouwishuseanoverheadasimpletransparenciesbyhandtoshowyourideasAfteryouhaveidentifiedalloftheimprovementsandopportunitieswhatwouldyourmaplooklikeYoumayreviseyourmapseveraltimesasyousimplifyMakesureyoucantraceallkeyproductandinformationflow–LookfordisconnectsoroversightsinyournewmapbyfollowingitthroughasagroupexerciseWhatarethenewLeadandCycletimes(Leadtimeisthekey)TeamTipsFutureStateMapping26ENERGIZERSCHICK-HIGHLYCONFIDENTIAL-RESTRICTEDFORINTERNALUSEONLYFromLearningtoSeebyMikeRotherandJohnShookFutureStateValueStreamMapProductionLeadtime=4.5DaysValueAddedTime=166seconds27ENERGIZERSCHICK-HIGHLYCONFIDENTIAL-RESTRICTEDFORINTERNALUSEONLYBenefitsofValueStreamMappingHelpsyouvisualizemorethanthesingle-processlevelClearlydefinesLeadandCycletimesHascross-functionalaccuracyLinksthematerial&informationflowsProvidesacommonlanguageandbasetoworkfromProvidesablueprintforimplementationMoreusefulthanquantitativetoolsTiestogetherLeanconcepts&techniques28ENERGIZERSCHICK-HIGHLYCONFIDENTIAL-RESTRICTEDFORINTERNALUSEONLYVerysimply,aleanvaluestreamshouldproducewhatthecustomerneedswhenitisneededandwiththehighestqualityandthelowestcost.Todothatallprocessesmustbelinkedfromthefinalcustomerbacktotherawmaterialandallnon-valueaddedactivitymustbeeliminated.29ENERGIZERSCHICK-HIGHLYCONFIDENTIAL-RESTRICTEDFORINTERNALUSEONLYLeadTimeReductionShorterLeadTime=SmallerdownstreamInventorySmallerOrderQuantity=SmallerdownstreamInventoryInventory=OrderQuantity/2+SafetyStockSafetyStock=DailyDemandxDemandStdDevxINVNORMAL(servicelevel)x√LeadTimeENRServiceLevel=98%30ENERGIZERSCHICK-HIGHLYCONFIDENTIAL-RESTRICTEDFORINTERNALUSEONLY