精益生产_衡量指标价值流分析.pdf
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1、1.?=?*?*?1.1?=?/?*100%1.1.1?=?-?1.1.2?=?-?1.2?=?*?1.2.1?=?/?*100%1.2.2?=?*?/?*100%?=?1.3?=?/?*100%?(Lean Mfg)?(Lean Mfg)?(value stream)?(value stream)?Objectives?At the end of this section,you will be able to:*?Define the terms Value stream and value stream Mapping*?Apply the steps for Mapping a Val
2、ue Stream to the Lean Simulation?At the end of this section,you will be able to:*?Define the terms Value stream and value stream Mapping*?Apply the steps for Mapping a Value Stream to the Lean Simulation?What is Value Stream?Definition?A value stream is all of the actions required to change raw mate
3、rials into a product delivered to the customer?Definition?A value stream is all of the actions required to change raw materials into a product delivered to the customer?What is Value Stream Map?Definition.?A visual depiction of the complete value stream,including material,product,and information flo
4、w?Benefits of Value Stream Mapping*?Provides a visual depiction of flow use as part of the decision making process*?Allows for identification of the sources of the seven wastes in the value stream*?Demonstrates the linkage between information flow and material flow*?Becomes the basis for developing
5、a plan for improving flow throughout the value stream?Current state value stream map?A current sate value stream map is the depiction of the complete value stream as it presently exists.the map inclidesmaterial,product,and information flow?Although the focus is on the manufacturing,the map could als
6、o be used to depict non-manufacturing activities?Current state value stream map?Assessing the current situation?The first in value stream mapping is assessingthe current situation by creating a current state map?Current state value stream map*?Choose a product or product family*?Depict the customer
7、requirements*?Follow the flow of the product from shipping,working backwards to the where raw materials arrive in the plant*?,?Draw the processing steps used to process,move and store the product?Current state value stream map?*?Input the appropriate process and inventory data?*?Draw the information
8、 flow?*?Draw a timeline depicting the lead time,showing value add and non-value add timeCurrent state mapping for a value streamCurrent state mapValue stream mappingFutures state map?future state value stream map?A future state value stream map is visual depiction of the goal of improvement actions,
9、the map includes material,product,and information flow?future state value stream mapping*?Begin with the current state value streams map,use the map to identify opportunities to eliminate waste.*?/takt time?Identify the customer demand rate/takttime*?follow the plan to“flow where you can,and pull(fr
10、om a controlled buffer with minimum and maximum levels)when you cannot flow”?future state value stream mapping*?Use tools,such as process flow analysis,to help analyze and identify waste reduction opportunities.*?Identify one single point in the production chain(the pacemaker process“)where you will
11、 schedule production*?Post the map in area that is clearly visible to all work group members on a continuous basis.future state value stream mapMeasurements:?*?Lead time in days is calculated by dividing inventory by customer requirements for one day for each operation,lead time should improve as wa
12、ste is eliminated fromthe process*?Value-add time in seconds is calculated by timing the operation as it changes form,fit,or finish of the product.value add time will be the same in both the current and future sate unless process is changedfuture state value stream mapMeasurements:?*?Dock to dock (D
13、TD)?Build to schedule (BTS)?First time through (FTT)?Overall equipment effectiveness(OEE),?total Cost*?The effectiveness of work group future state actions should be reflected by an improvement in these metrics?*?*?.?.?.*?*?*?*?.?“?”?.?“?”?*?(?)?*?MPS?MRP?*?*?*?*?*?*?*?*?*?*DTD?(?)?(value added oper
14、ation)?*DTD?Buffer?transfer?inspection,rework?:*?*?*?*?*?*?*?*?*?*?1.?2.?.3.?,?4.?5.?6.?7.?.?.?“?”?.?.?Mapping IconsValue Stream MappingMapping IconsValue Stream MappingMapping IconsValue Stream Mapping?*?.?.?.?.?*?*?“?”?”?”?*?“?”?*?*?*?.?.?Current State Stream Exercise*?“?”?*?Complete the current s
15、tate map for simulation?.?follow the process to create a current state map provide data for your area?Data Collection*?Walk the line-collect information beginning at shipping and working upstream.?Collect your own information for the value stream,understanding the entire material and information flo
16、w.?transfer information to the current state map?Learning Points-1*?An unstable process promotes unsafe work conditions and practices*?A mass production system generates large amounts of waste*?overproduction and high levels of inventory hide production problems,magnify the impact of quality problem
17、,and delay feedback?Learning Points-2*?most of the production time is non-value added*?an unstable production process makes effective problem solving difficult,if not impossible*?an unstable production process forces crisis management instead of strategic leadership?Learning RESULTS:*?operator under
18、standing and ownership of the lean vision*?improved safety*?Improved customer satisfaction in terms of quality,cost,and time(manufacturing delivery time)?Lean manufacturing measurables*?-DTDDock to Dock*?-FTTFirst time through*?-BTSBuild to schedule*?-OEEOverall equipment effectiveness?Dock to Dock
19、TimeDTDDock to Dock Time(DTD)*Definition?.?the elapsed time between the unloading of raw materials and the release of finished goods for shipment.?DTD?the total dock to dock time for a product includes the time that a product spends as raw material,work-in process and as a finished product in plant,
20、prior to being relaesed.?(DTD)(DTD)?(MCT)(MCT)?(DTD)(DTD)(DTD)(DTD)?-DTDDTD?DTD-?DTD is measure(in hours)of the speed of material through the plant,not the speed of the process.?DTD*Benefits?.DTD?FTTdock to dock time is improved by decreasing inventories which leads to less material handing and stor
21、age.this result in fewer opportunities to damage parts.There by improving first time through.?.?DTD?OTD?improved dock to dock time leads to improved ability to support the order to delivery(OTD)target.?.?lower material handing.Obsolescence.And inventory carrying costs all lead to improved total cost
22、 numbers.?DTD*?Why:?.?PLANTS MUST ELIMINATE WASTE AND MOVE TOWARDS CUSTOMER“PULL”SYSTEMS.?.?(?)?By building large buffers you produce more parts(increase The speed of your process)but slow down the speed of materials.?.?,?.decreasing inventories leads to less material handing and storage,which resul
23、ts in fewer opportunities to damage parts.?DTD*?Why:?.?.DTD?.?,?.?DTD*?Why?.DTD?value added operation?.DTD?.?wait?.?stagnation?.?buffer?.?storage?.?Transfer?.?Inspection?.?Rework?DTD*?where:1?.?-?.?.?.raw material-purchase part(control part)begin counting when it is received in the plant.Even on con
24、signment.Because it is already in its product from already in its product form.?.?Raw material that is changed its product form?DTD*?where?2?.?Work-in-process(WIP),including material in repair rework areas,and all buffers?.?-?DTD?Finished goods end item products all finished goods ontaining the cont
25、rol part are included in the DTD calculation until they physically shipped form the dock?DTD*?when:?Data should be collected at the same time which best represents the operating pattern of a product line?DTD*?.?.?.?-DTD*?.?.?.?DTD*?.?/?.?.?.?.?.?-DTD*?DTD?.?.?.?.?.?.?.?.?.?-DTD*?DTD?.DTD-?.?-?-DTD?D
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- 生产 衡量 指标 价值 分析
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