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1、Part I:Current State Mapping第一部分：现状图Production ControlSchedulingCustomer客户Suppliers 供应商Purchasing?Materials?Manpower?PriorityManpowerAvailableMake PartsPaintDeptMaterialAvailableNeed PartsProcess Mapping Benefits过程图的优点l lObtain current plant operating informationObtain current plant operating inform
2、ationl l获得当前车间的业务资料获得当前车间的业务资料l lObtain current metrics informationObtain current metrics informationl l获得当前的数据资料获得当前的数据资料l lIdentifies inventory and where it is storedIdentifies inventory and where it is storedl l区分在库及其地点区分在库及其地点l lShows material flowShows material flow表明原料的流动表明原料的流动l lGives you a
3、baseline on where you are and a Gives you a baseline on where you are and a tool to chart your progress after implementing tool to chart your progress after implementing improvements within the plantimprovements within the plant在车间内实行改进在车间内实行改进后，给你一个绘制你进步的基点和工具后，给你一个绘制你进步的基点和工具The BIG Picture整体性Usin
4、g the value stream analysis means working on the big picture,not just the individual processes;improving the whole,not just optimizing the parts.运用价值流分析意味着在整体上工作，不仅仅是个别的生产过程；不只是优化局部而是提高全部。This is not a computer process这不是一个使用计算机的过程Value Stream Mapping is a pencil and paper tool Value Stream Mapping
5、is a pencil and paper tool that helps you to see and understand the flows that helps you to see and understand the flows of material and information as a product makes of material and information as a product makes its way through the value stream.its way through the value stream.价值流图是以价值流图是以笔和纸为工具来
6、帮助你在产品通过价值流时看清笔和纸为工具来帮助你在产品通过价值流时看清和理解物料和信息的流向。和理解物料和信息的流向。Material and Information Flow材料和信息流 The movement of material is usually what The movement of material is usually what comes to mind when we discuss“production comes to mind when we discuss“production flow”.flow”.当我们谈论产品流程时，通常想到的是材当我们谈论产品流程时，
7、通常想到的是材料的流动。料的流动。But there is another flow-of information-But there is another flow-of information-which tells each process what to make or do which tells each process what to make or do nextnext。但还有一种但还有一种-信息流，它能告诉你每个过信息流，它能告诉你每个过程做什么和将要做什么。程做什么和将要做什么。You must map both of themYou must map both of t
8、hem.你必须同时图你必须同时图你必须同时图你必须同时图析他们析他们析他们析他们Production FlowinformationmaterialUsing the Mapping Tool 运用图析工具 First,we draw the First,we draw the current state map by current state map by gathering gathering information directly information directly from the shop floor.from the shop floor.首先，我们应运用从首先，我们应运
9、用从车间直接采集的信息车间直接采集的信息来绘制现在状态图。来绘制现在状态图。Product Family产品系列产品系列Current State Drawing现状图现状图Future State Drawing将来图将来图Work Plan计划计划Using the Mapping Tool From this,we begin From this,we begin to draw our ideal,or to draw our ideal,or improved,operation;improved,operation;our our Future State MapFuture St
10、ate Map.从这里我们开始画理从这里我们开始画理想和改良的操作；想和改良的操作；我我们的将来状态图。们的将来状态图。Product Family产品系产品系列列Current State Drawing现状图现状图Future State Drawing未来状态图未来状态图Work Plan工作工作计划计划Using the Mapping Tool The final step is to The final step is to implement a plan to implement a plan to transition the plant transition the pla
11、nt from the current from the current state to the future state to the future state.state.最后的步骤是执最后的步骤是执行从现在到将来状态行从现在到将来状态工厂转变的计划工厂转变的计划Product FamilyCurrent State DrawingFuture State DrawingWork PlanThe Icons Used.所用图标We use symbols,or icons,to represent We use symbols,or icons,to represent processe
12、s and flow.processes and flow.我们用标记，图标来代我们用标记，图标来代替过程和流向。替过程和流向。AssemblyABC Corp.Movement of Production Materials Movement of finished goods to the CustomerInventory Rail Shipments _/wkMaterial Queue (sequenced)Conveyance RoutePull of Material from one process to next_ hour_ hour Tank Shipment_/wkTh
13、e Icons Used(contd)Electronic Information FlowProduction Schedule Manual Information FlowweeklySignal Production Card Production Instruction FlowIndicates path of Production Instruction CardIndicates path of Material with withdraw cardSequential Production ScheduleProduction Instruction CardMaterial
14、 Withdraw Card MarketplaceABCBuffer or Emergency StockABCMapping Tips绘图技巧 Collect data from the actual floor.Collect data from the actual floor.从现行的工厂收集资料从现行的工厂收集资料 Walk the entire door-to-door value stream.Walk the entire door-to-door value stream.沿着整个门到沿着整个门到门的价值流走。门的价值流走。Do not rely on informatio
15、n that you do not obtain Do not rely on information that you do not obtain yourself.yourself.不要依赖不是你亲自得到的信息不要依赖不是你亲自得到的信息。Even if several people are involved,map the whole value Even if several people are involved,map the whole value stream yourself.stream yourself.尽管有很多人参加，你还是要自己绘制整尽管有很多人参加，你还是要自己绘
16、制整个价值流。个价值流。Resist the temptation to use a computer.Resist the temptation to use a computer.抵制住计算机的抵制住计算机的诱惑诱惑Add Lead Times加上生产周期TransferWasherAssemblyShippingRaw Hsg5 daysC/T=20 secC/O=1 hrUptime:65%C/T=10 secC/O=0Uptime:95%C/T=61 secC/O=10 minUptime:100%20,000 A15,000 B25,000 A18,000 B15,000 A 8,
17、000 B22,000 pcs/day -14,000“A”-8,000 “B”Tray=20 pieces2 shiftsState Street AssemblyMachiningWasherAssemblyShippingRaw Hsg5 daysC/T=20 secC/O=1 hrUptime:65%C/T=10 secC/O=0Uptime:95%C/T=55 secC/O=10 minUptime:100%20,000 A15,000 B25,000 A18,000 B15,000 A 8,000 B22,000 pcs/day -14,000“A”-8,000 “B”Tray=2
18、0 pieces2 shiftsAltona AssemblyTues&ThursTues&ThursProduction ControlForecastWeeklyForecastWeeklyWeekly ScheduleDaily Ship Schedule1x Daily5 days20 sec3.8 days10 sec55 sec4.6 days3.2 days16.6 days85 secCompare Production Lead Time with Value-added Time比较生产周期时间和增值时间Port Casting18,400 pcs/day -12,000“A”-6,400 “B”Box=20 pieces2 shifts各个部署现状图的测量数据 -针对AIR MAX FAO3 库存库存:原材料原材料/生产中在库生产中在库/完成品在库完成品在库 必须在库时间必须在库时间 工人数量工人数量/班次班次 工程周期工程周期/平均停机平均停机/转换时间转换时间/机器数量机器数量 计划产量计划产量/实际产量实际产量/不良不良/重修重修 纳期时间纳期时间(DTD)/DTD)/直行率（直行率（FTT)/FTT)/整体效率（整体效率（OEEOEE）