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1、Lean Manufacturing Value Stream Mapping1ENERGIZER SCHICK-HIGHLY CONFIDENTIAL-RESTRICTED FOR INTERNAL USE ONLYWhat is Lean?Lean is a that focuses on:Creating value for the Customer Eliminating Waste Continuous incremental improvement2ENERGIZER SCHICK-HIGHLY CONFIDENTIAL-RESTRICTED FOR INTERNAL USE ON
2、LYWhat is a Value Stream?“All of the actions,value or non value added that are required to bring a product from concept to launch or from raw material order to delivery.”From“Lean Lexicon”3ENERGIZER SCHICK-HIGHLY CONFIDENTIAL-RESTRICTED FOR INTERNAL USE ONLYOrder Fulfillment Value StreamIdeally,wed
3、want the materials,information and cashto flow smoothly(without interruption)and as quickly as possible through this stream.SalesOrderReceiptRMOrder&ReceiptManufacturingPackagingDistributionDelivery/Service4ENERGIZER SCHICK-HIGHLY CONFIDENTIAL-RESTRICTED FOR INTERNAL USE ONLYLean Elements5ENERGIZER
4、SCHICK-HIGHLY CONFIDENTIAL-RESTRICTED FOR INTERNAL USE ONLYValue“What is the willing to Pay for?”3 Types of Customers:The external end-user or paying customerThe downstream customer of any internal upstream process.Your company as the customer of external suppliers.6ENERGIZER SCHICK-HIGHLY CONFIDENT
5、IAL-RESTRICTED FOR INTERNAL USE ONLYFlowIdeal flow=1 piece at a timeRate determined by customer demand-Takt time Work balanced for each person or machineTravel distance for materials&people minimizedStandard Work utilizedFlow what you can Pull what you cantRequires that all steps in the process be:C
6、apable=Right every timeAvailable=Always able to runAdequate=Capacity to avoid bottlenecks7ENERGIZER SCHICK-HIGHLY CONFIDENTIAL-RESTRICTED FOR INTERNAL USE ONLYPhases of Lean JourneyPhase 1-Identify/Map Value StreamsPhase 2-Prioritize opportunitiesPhase 3-Utilize Lean tools to eliminate wastePhase 4-
7、Control the flow Phase 5-Lean metricsPhase 6-Re-evaluate Value Streams and begin again8ENERGIZER SCHICK-HIGHLY CONFIDENTIAL-RESTRICTED FOR INTERNAL USE ONLYIt All starts with Waste IdentificationIdentify all forms of Waste throughout our entire Value Stream before:Reducing the waste or Eliminating t
8、he wasteThis will enable us to prioritize our efforts and focus on the high potential events first.9ENERGIZER SCHICK-HIGHLY CONFIDENTIAL-RESTRICTED FOR INTERNAL USE ONLY8 WastesOverproductionInventoryWaitingTransportingUnnecessary processingUnnecessary motionDefectsUnder utilization of people10ENERG
9、IZER SCHICK-HIGHLY CONFIDENTIAL-RESTRICTED FOR INTERNAL USE ONLYOver-ProductionProducing more than what the customer really wants.Ways to Overcome:Reduce setup timesSynchronize time and amount of processesCreate compact layouts and visibility11ENERGIZER SCHICK-HIGHLY CONFIDENTIAL-RESTRICTED FOR INTE
10、RNAL USE ONLYInventoryExcess inventory requires handling,space,$,people,and paperwork.Ways to Overcome:Synchronize work flow to reduce accumulationShorten setup timeReduce lead timeCellular layoutsZero Quality DefectsReducing all other wastes reduces the waste of inventory12ENERGIZER SCHICK-HIGHLY C
11、ONFIDENTIAL-RESTRICTED FOR INTERNAL USE ONLYWaitingWaiting for upstream processes due to poor layout,unbalanced work load or equipment downtime.Ways to Overcome:Synchronize work flowBalance uneven loads by flexible workers and equipmentImplement preventive maintenance to eliminate machine down-time1
12、3ENERGIZER SCHICK-HIGHLY CONFIDENTIAL-RESTRICTED FOR INTERNAL USE ONLYTransportationTransportation adds No value to the product.Rather than improve the transportation:Reduce itEliminate it.Ways to Overcome:Establish layout and locations which reduces or eliminates transportation14ENERGIZER SCHICK-HI
13、GHLY CONFIDENTIAL-RESTRICTED FOR INTERNAL USE ONLYUnnecessary ProcessingSame data entered into 3 different information systems.(SAP,Access,Excel)All unnecessary,or Non-Value Added,processing steps should be eliminatedWays to Overcome:Question if process is necessary at allSimplifyUse Standard WorkRe
14、duce Handoffs/approvals15ENERGIZER SCHICK-HIGHLY CONFIDENTIAL-RESTRICTED FOR INTERNAL USE ONLYUnnecessary MotionMotion of people,machines,and products is waste.Ways to Overcome:Study motion and eliminate or reduce motion through improved layouts.Cellular ManufacturingRethink material storageJob/Task
15、 Combinations16ENERGIZER SCHICK-HIGHLY CONFIDENTIAL-RESTRICTED FOR INTERNAL USE ONLYDefects(Correction)Making defective product is pure(muda)waste.Focus on preventing defectsNot finding and repairing defectsWays to Overcome:Mistake-proof to prevent defectsNever Pass defectsStandard Work17ENERGIZER S
16、CHICK-HIGHLY CONFIDENTIAL-RESTRICTED FOR INTERNAL USE ONLYWaste of Underutilizing PeopleThe eighth waste is not fully utilizing the time and talents of people.Who are the“real”experts?and what do they know?18ENERGIZER SCHICK-HIGHLY CONFIDENTIAL-RESTRICTED FOR INTERNAL USE ONLYPurpose of Value Stream
17、 MappingThe purpose of the value stream map is to look at the big picture and to develop a“future-state”map by eliminating all non-value added activities and minimizing all non-value-added but required activities.19ENERGIZER SCHICK-HIGHLY CONFIDENTIAL-RESTRICTED FOR INTERNAL USE ONLYBasic Current St
18、ate MAPPING TIPS 1 Cross-functional Team completes the map Start at the customer end Walk the actual pathways of both material and information flow.Draw by hand in pencil.20ENERGIZER SCHICK-HIGHLY CONFIDENTIAL-RESTRICTED FOR INTERNAL USE ONLYValue Stream Mapping IconsProcess Icons21ENERGIZER SCHICK-
19、HIGHLY CONFIDENTIAL-RESTRICTED FOR INTERNAL USE ONLYValue Stream Mapping IconsInformation Flow Icons22ENERGIZER SCHICK-HIGHLY CONFIDENTIAL-RESTRICTED FOR INTERNAL USE ONLY23ENERGIZER SCHICK-HIGHLY CONFIDENTIAL-RESTRICTED FOR INTERNAL USE ONLYProduction Lead Time=23.5 daysValue Added Time=184 Seconds
20、From Learning to See by Mike Rother and John ShookCurrent State Map24ENERGIZER SCHICK-HIGHLY CONFIDENTIAL-RESTRICTED FOR INTERNAL USE ONLYFuture State QuestionsHow do we focus on the Lead time?Understand the takt timeWhat area in the process triggers production?Will we build to shipping or to a supe
21、rmarket?Where can we use continuous flow?What items or Events require Process MapsHow do we simplify Where do we reduce travel&redundancy?What process improvements can we do?25ENERGIZER SCHICK-HIGHLY CONFIDENTIAL-RESTRICTED FOR INTERNAL USE ONLY Use the list of future state questionsHave your cross-
22、functional group brainstormUtilize“outside”folks and yourself to question everythingYou can sketch future state ideas at the table to discussIf you wish use an overhead a simple transparencies by hand to show your ideasAfter you have identified all of the improvements and opportunities what would yo
23、ur map look likeYou may revise your map several times as you simplifyMake sure you can trace all key product and information flow Look for disconnects or oversights in your new map by following it through as a group exerciseWhat are the new Lead and Cycle times(Lead time is the key)Team TipsFuture S
24、tate Mapping26ENERGIZER SCHICK-HIGHLY CONFIDENTIAL-RESTRICTED FOR INTERNAL USE ONLYFrom Learning to See by Mike Rother and John ShookFuture State Value Stream MapProduction Lead time=4.5 Days Value Added Time=166 seconds27ENERGIZER SCHICK-HIGHLY CONFIDENTIAL-RESTRICTED FOR INTERNAL USE ONLYBenefits
25、of Value Stream MappingHelps you visualize more than the single-process levelClearly defines Lead and Cycle timesHas cross-functional accuracyLinks the material&information flowsProvides a common language and base to work fromProvides a blueprint for implementationMore useful than quantitative tools
26、Ties together Lean concepts&techniques28ENERGIZER SCHICK-HIGHLY CONFIDENTIAL-RESTRICTED FOR INTERNAL USE ONLY Very simply,a lean value stream should produce what the customer needs when it is needed and with the highest quality and the lowest cost.To do that all processes must be linked from the fin
27、al customer back to the raw material and all non-value added activity must be eliminated.29ENERGIZER SCHICK-HIGHLY CONFIDENTIAL-RESTRICTED FOR INTERNAL USE ONLYLead Time ReductionShorter Lead Time=Smaller downstream InventorySmaller Order Quantity=Smaller downstream Inventory Inventory=Order Quantity/2+Safety StockSafety Stock=Daily Demand x Demand Std Dev x INVNORMAL(service level)x Lead TimeENR Service Level=98%30ENERGIZER SCHICK-HIGHLY CONFIDENTIAL-RESTRICTED FOR INTERNAL USE ONLYVSM References31ENERGIZER SCHICK-HIGHLY CONFIDENTIAL-RESTRICTED FOR INTERNAL USE ONLY演讲完毕，谢谢观看！