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1、CAF STA 10/2004 供應商培訓,精实生产 衡量指标/价值流分析,何謂精實製造(Lean Mfg),它是什麼? 是一種在價值流(value stream)中藉由排除浪費以提昇流動性，使其能獲致更短的前置時間，從而提供高品質、低成本的製造哲學 由產品開發、程序工程、營運管理及企業總管理作業等所組成的一整合性系統，其能為顧客提供價值及帶給人們尊嚴 它不是什麼? 僅是裁減員額數,价值流图分析,课程目标 Objectives,在完成此一课程你将能 At the end of this section, you will be able to : *定义期间价值流及价值流图分析 Define
2、the terms Value stream and value stream Mapping *應用价值流图分析实施步骤以模拟精实 Apply the steps for Mapping a Value Stream to the Lean Simulation,价值流是什么 What is Value Stream,定义 Definition 价值流是將生产物料改变到产品运交给客 户之間全面性需求措施 A value stream is all of the actions required to change raw materials into a product delivered
3、to the customer,价值流图是什么 What is Value Stream Map,定义 Definition . 一个目视化以描述整体价值流， 包含原材料产品及咨訊流分析图 A visual depiction of the complete value stream, including material, product, and information flow,价值流图分析之利益 Benefits of Value Stream Mapping,*提供流動视觉的描述（以）用作零件制程程序的决策 Provides a visual depiction of flow us
4、e as part of the decision making process *在价值流中以提供鉴认七大浪费缘由 Allows for identification of the sources of the seven wastes in the value stream *验证咨询流与材料流的關连性 Demonstrates the linkage between information flow and material flow *通过价值流以作为工厂发展改善流程基础与消除浪费 Becomes the basis for developing a plan for improvin
5、g flow throughout the value stream,现状价值流图 Current state value stream map,一个现状价值流图是为完整价值流目前存在的视觉描述。包含物料，产品，即咨询流 A current sate value stream map is the depiction of the complete value stream as it presently exists. the map inclides material, product, and information flow 虽然关注在生产制造，也可以用在描述非生产活动。 Althou
6、gh the focus is on the manufacturing, the map could also be used to depict non-manufacturing activities,现状价值流图 Current state value stream map,评估现状 Assessing the current situation 价值流图分析第一步骤是评估现实状况以制作现状图 The first in value stream mapping is assessing the current situation by creating a current state
7、map,现状价值流图 Current state value stream map,*选择一产品或产品族 Choose a product or product family *描述顾客需求 Depict the customer requirements *反向跟随产品从交货，生产作业，到原料入厂 Follow the flow of the product from shipping, working backwards to the where raw materials arrive in the plant *绘制产品在使用的過程,移动与储存阶段程序 Draw the process
8、ing steps used to process, move and store the product,现状价值流图 Current state value stream map,*记入適當的程序与库存数据 Input the appropriate process and inventory data *绘制咨询流 Draw the information flow *绘制时间线描述前置时间，表示出有附加值 与无附加值时间 Draw a timeline depicting the lead time, showing value add and non-value add time,C
9、urrent state mapping for a value stream,Current state map,Value stream mapping,Futures state map,未来价值流图 future state value stream map,未来价值流图是一目视可描述改善對策目标包含物料，产品，及咨询流 A future state value stream map is visual depiction of the goal of improvement actions, the map includes material, product, and inform
10、ation flow,未来价值流图析步骤 future state value stream mapping,*着手以现状价值流图鉴别消除浪费机会 Begin with the current state value streams map, use the map to identify opportunities to eliminate waste. *确认顾客需求/takt time Identify the customer demand rate /takt time *依计划执行（从控制缓行最小于最大水准） follow the plan to “flow where you c
11、an, and pull (from a controlled buffer with minimum and maximum levels ) when you cannot flow”,未来价值流图析步骤 future state value stream mapping,*使用工具如流程分析以协助分析及鉴别浪费降低的机会 Use tools, such as process flow analysis,to help analyze and identify waste reduction opportunities. *确认在生产鍊单一点（制程速率点）可排生产计划 Identify o
12、ne single point in the production chain (the pacemaker process “)where you will schedule production *张贴价值流图在作业区给全部工作人员清楚目视為持续改进的基础 Post the map in area that is clearly visible to all work group members on a continuous basis.,future state value stream map Measurements :衡量指标,*前置时间天数是以库存依據顾客需求在各作业間，计算前
13、置时间必须从制程浪费消除改善 Lead time in days is calculated by dividing inventory by customer requirements for one day for each operation, lead time should improve as waste is eliminated from the process *附加值时间秒数是由作业时间计算，如变更外形 安装，或产品修饰，附加价值时间将相同于现在与未来状况除非制程被变更 Value-add time in seconds is calculated by timing th
14、e 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 changed,future state value stream map Measurements :衡量指标,*指标 Dock to dock (DTD) Build to schedule (BTS) First time through (FTT) Overall equipment effe
15、ctiveness (OEE), total Cost *工作小组未来状况对策绩效必须由改善数据反应 The effectiveness of work group future state actions should be reflected by an improvement in these metrics,价值流图析,*价值流图析是一种完整且有系统性的方法 *使用价值流图析之意义是可在巨观的大范圍下作业。亦可拘於局部性.區域性.或個別性的作業. *因此他是可进行全面整体性而不仅是最佳化个别部分。,价值流图析,*一个价值流图析是指归集一产品在其生产过程中所有的活动：包括哪些有增加附加價
16、值及没有增加价值的活动。 *价值流图析将是包含有附加值作业与无附加值作业调查检讨，用以改善制程提升整体生产力的一项系统手法,价值流图析,*价值流是为产品已当前通过其基本生产过程所进行的全部活动，可分成 .从原材料到产品交到顾客手中 “生产流” .从概念到投产 “设计流”,价值流图析,*从顾客到供应商跟随产品的生产反向路径将材料流与讯息流以代表图形仔细绘出每個过程以便于了解掌握制程中的 (关键问题) *分析检讨，关键问题，提出改善对策后，再次绘制一期望的，未来状態的价值流图，作为目标蓝图及执行改善活动,生產管理,生產排程MPS,顧客,協力廠商,採購MRP,物料? 人力? 優先順序?,人員是否足夠
17、,時間拖延,生產部品,塗裝部門,物料是否足夠,時間拖延,催料,需要物料,庫存,庫存,不準確的顧客訂單,不具信賴的製程及供應商,交貨單,不及時、不正確的庫存回報,价值流图析基本功能,*价值流图析可以帮助你看到的不仅仅是单一的生产制程而是整体的生产流程 *价值流图析可以帮助你发现生产制程中的浪费的根源 *价值流图可以为生产过程提供共同语言 *价值流图可显示讯息流与材料流的联系 *没有其他工具能做到此项功能,价值流图析基本功能,*价值流图是为实现精实生产的蓝图以作为改善实施计划的基础 *如果要设计一个新的生产制程或者要改变一个现有的价值流就将精实生产理论概念与技术实务结合 *进行价值流图分析检讨绘出
18、 精益的价值流未来图,价值流图,*进料仓库到出货仓时间 *DTD附加價值正味(实质)作业 (value added operation)仅量少分 *DTD绝大部分时间是无附加值 缓行（Buffer） 停滞 库存 搬运 （transfer） 检查，返工（inspection ,rework）,价值流图析应用,价值流改善与制程改善在公司管理改进都是必要的: *价值流改善重点在于材料和讯息的流 动改善 *制成改善则重点在人与过程中消除 浪费,价值流图析应用,价值流现状与未来图的关系是双向的循环，相互作 用并应努力实现计划目标,现状图,未来图,改善执行,改善计划,团队努力,价值流图析应用,达成未来目标
19、计划 *设计一个精实的流程 *掌握价值流的背后动力 *需要一个未来目标 *需要一个按步就搬的工作计划 应有明确的时间及责任指定,价值流图析应用,*生产管理有一种讯息流通知制程现在生产什么，再下一次生产什么之计划讯息 *精实生产实务中讯息流被视为与材料流一样重要，在价值流图析进行中必须都要繪入並执行分析检讨,价值流图绘制,*使用一套符号（圖标）表示生产过程和流动必要时可以增加符号运用，但是必须在公司内部作程序规定，使每一个人都能绘制与理解将实施的精实生产价值流图。 *从一个整体产品价值流可将各独立工程放大作细部分析或拓展到工厂以外的价值流图分析,价值流图绘制,1.开始先从进料到出貨作观察了解制程
20、的流動和顺序。 2.然后沿实际材料和讯息流亲自收集与记录每个过程当时狀態咨询. 3.从最终出货区（此是与顾客最直接关聯点）向前工程走,开始进行价值流分析,价值流图析应用,4.使用马表与实际观察，不要依赖文件资料，标准工时等数据，因为文件资料常与实际事实不相符合 5.价值流未来图的设想能力决定在于实际状况的了解与记录资料及時間观测 6.即使是为多人共同参与价值流图析，仍必须是个人完成全部价值流图析，否则无法完全了解掌握整体价值流状况,价值流图绘制,7.使用铅笔先做草图绘制：正试图绘制时还是使用铅笔 .是用铅笔亲手绘制可以不停的画，进行中会想到更多 要什么咨询 .手绘自己进行是理解“材料與讯息流”
21、的关键 .手绘自己进行可以将注意力集中在价值流中 .手绘自己进行可以提高作图析之能力,Mapping Icons,Value Stream Mapping,Mapping Icons,Value Stream Mapping,Mapping Icons,Value Stream Mapping,价值流改善,*价值流图示意 .以目视化表示物流与咨询流 .提供一价值流的蓝图供作执行 .让每一个人都必须对范围有所了解 .始能达成精实化的流,价值流改善,*任何改进最重要的是从最终顾客需求做起，价值流图分析要从顾客要求为起点 *创造增进价值流，您必须要有一“愿景” 价值流图析能帮助你专注，看”愿景”的理
22、想及改善状態,价值流管理,*一产品之“价值流”会跨越几个部门或公司外界，一般的改善活动常常会局限在个别区域，而不是以整体价值流作基础 *要消除此管理的死角，需要有一位了解产品系列价值流并能推动改善的领导人 *他必须向最高管理者在经营管理会议汇报精实生产状况,价值流管理,*精实生产的执行 .管理层必须规划及主导价值流的导入 .辨识每一个产品族的整个价值流 这是精实生产思考的主要步骤,现状图析案例 Current State Stream Exercise,*假如你希望的工作区，你的企业在未来成为“精实”那么你就必须先学会学习有关现在的工作区采取价值流的观点 *完成现状图析模拟 Complete
23、the current state map for simulation .跟随制程制作现状图提出数据在您的区域 follow the process to create a current state map provide data for your area,收集数据 Data Collection,*行走于生产线 收集咨询起点在交货與作业逆向 Walk the line-collect information beginning at shipping and working upstream .为价值流收集你拥有的咨询了解全部原物料与咨询流 Collect your own info
24、rmation for the value stream, understanding the entire material and information flow .转换咨询到现状图 transfer information to the current state map,学习点Learning Points - 1,*实践提升不稳定制程 及不安全工作条件 An unstable process promotes unsafe work conditions and practices *大量生产系统产生大额浪费 A mass production system generates l
25、arge amounts of waste *过量产與高库存隐藏生产问题，扩大品质问题衝擊延迟反馈 overproduction and high levels of inventory hide production problems, magnify the impact of quality problem, and delay feedback,学习点Learning Points - 2,*大多生产时间是无附加值 most of the production time is non-value added *不稳定的生产制程造成有效解决问题的困难 an unstable produc
26、tion process makes effective problem solving difficult, if not impossible *不稳定生产制程迫使危机管理取代了策略领导 an unstable production process forces crisis management instead of strategic leadership,学习点效果 Learning RESULTS:,*作业人员谅解及授权 精实愿景 operator understanding and ownership of the lean vision *改善安全 improved safet
27、y *改善顾客满意点 品质 成本 时间 （生产交期时间） Improved customer satisfaction in terms of quality, cost, and time (manufacturing delivery time ),精實推展 衡量指標,精实生产 衡量指标 Lean manufacturing measurables,*进料仓库道出货仓库时间- DTD Dock to Dock *首次合格率 - FTT First time through *依排成生产 - BTS Build to schedule *总何设备效率 - OEE Overall equipm
28、ent effectiveness,进料到出货时间 Dock to Dock Time DTD,Dock to Dock Time (DTD),*Definition 定义 .从原物料下货到完成成品出货之间的过去时间 the elapsed time between the unloading of raw materials and the release of finished goods for shipment .总DTD时间为产品耗费时间如原物料，制程作业，与 在厂完成品出货前在品的时间 the total dock to dock time for a product includ
29、es the time that a product spends as raw material, work-in process and as a finished product in plant, prior to being relaesed.,進料倉庫,成品倉庫,進料倉庫到出貨倉庫時間 (DTD),製造週期時間(MCT),生產製造過程,衡量指標(DTD),衡量指标-DTD,DTD 從进料仓库到出貨仓库間时间 指原料進廠製成完成品準備出貨的時間 包含製造週期時間 DTD - 是衡量（时数）物料通过工厂的 速度，不是程序的速度 DTD is measure (in hours) of
30、the speed of material through the plant, not the speed of the process.,衡量指标 DTD,*Benefits 利益 .DTD时间改善以减少库存由较少的物料管理与库存结果较少几率 损坏部品改善FTT dock to dock time is improved by decreasing inventories which leads to less material handing and storage .this result in fewer opportunities to damage parts. There by
31、 improving first time through. .改善DTD时间可增进能力支援OTD目标 improved dock to dock time leads to improved ability to support the order to delivery (OTD) target. .减少物料管理，废弃，及库存搬运成本，全部可以改善总成本数 lower material handing. Obsolescence. And inventory carrying costs all lead to improved total cost numbers.,衡量指标 DTD,*
32、为什么 Why: .工廠必須消除浪費與改變到顧客拉式系統 PLANTS MUST ELIMINATE WASTE AND MOVE TOWARDS CUSTOMER “PULL”SYSTEMS. .設置巨大緩衝區生產過多零件(增快製程速度)但是降低了物料速度 By building large buffers you produce more parts (increase The speed of your process ) but slow down the speed of materials. .減少庫存可以減少物料管理及儲存,結果減少損壞零件的機會. decreasing inve
33、ntories leads to less material handing and storage, which results in fewer opportunities to damage parts.,衡量指标 DTD,*为什么 Why: .衡量生产库存週转的时间管理 .DTD日程越短则週转越快 .有效管理库存资金,降低生产成本 .快速对应顾客需求,衡量指标 DTD,*为什么 Why： .DTD附加价值（实质）作业（value added operation）仅量少分 .DTD 绝大部分时间是 无附加价值 .等待 （wait） .停滞（stagnation） .缓行 （buffer）
34、 .存储 （ storage） .搬 运 （Transfer） .检查 （Inspection） .返工（Rework）,衡量指标 DTD,*何处 where :1 .原物料 - 购买的零件（管制部品）接收进入工厂开始计数.运委托制件.因为已经产品構成. raw material-purchase part (control part) begin counting when it is received in the plant .Even on consignment. Because it is already in its product from already in its pro
35、duct form. .原物料变更成为产品构成 Raw material that is changed its product form,衡量指标 DTD,*何处 where ：2 .制程工作，包括物料在修理返工区域及全部缓衝区 Work-in-process (WIP), including material in repair rework areas, and all buffers .完成产品-所有完成品包含管制部品并入DTD计算直 到被从马头交运 Finished goods end item products all finished goods ontaining the co
36、ntrol part are included in the DTD calculation until they physically shipped form the dock,衡量指标 DTD,*何时 when: 数据收集时必须在作业型態表现优良的产品线上進行 Data should be collected at the same time which best represents the operating pattern of a product line,衡量指标 DTD,*如何做 .降低原材料库存 .降低安全库存量 .提高进料频度,衡量指标 -DTD,*如何做 . 降低成品库
37、存 .降低安全库存 .提高交货频度,衡量指标 DTD,*如何做 .减少在制品/制程高效率化 .目视化以及 防误措施 .一个流 小批量 .作业依排程生产 .推展全员生产性保养 .缩短转换时间,衡量指标-DTD,*降低总 DTD 时间 . 制程工程分析改善物流效率. 消除停滞减少搬运 . 制程作业分析改善. 降低周期时间 .消除不良. 提高首次合格率 .排除稼动损失. 提高总合设备效率 .善用价值流图析,衡量指标-DTD,*降低总 DTD 时间 .DTD-从价值流图析能作用明确有效展现 .应用工业工程分析改善效率 並进行时间缩短改善 （ 时间）- 是各企业公司同样拥有之唯一 等量资源,衡量指标-D
38、TD,单作业 DTD= 复合作业 DTD=,总管制数,线末速率,DTD作业1+DTD作业2+DTD作业3,线末速率,Total Dock To Dock Calculation,(Single Operation ) DTD = (Multiple Operation) DTD=,Total Units of Control Part,End of Line Rate,DTD(Operation1)+DTD(Operation2)+DTD(Operation),End of Line Rate,END,首次合格率FTT First Time Through,衡量指标FTT,定义Definiti
39、on 1 .FTT是为在一完整制程生产中，第一次既符合品质要求的产品件数的百分比率 不含被報廢，返工，重试验，線外修理，返回件数 First Time Through is the percentage of units that complete a process and quality guidelines the first time without being scrapped, return, retested, repaired, or returned,衡量指标FTT,定义Definition 2 .FTT是衡量生产制程的品质 it is a measure of the qu
40、ality of the manufacturing process .可应用FPS程序工具改善FTT (防误措施，幕式化工厂，快速转换) we can improve our FTT by applying our FPS process and tools (error proofing, visual factory & quick changeover).,衡量指标FTT,FTT首次合格率 投入制程总件数-（报废+返工+重试+线外修理+退回件数） Units entering process (Scrap + returns + retests + repaired off-line
41、+returns),投入制程总件数,Units entering process,衡量指标-FTT,利益 Benefits 1 .提升制程/品质不良減少，库存降低,改善DTD时间 Increased process/out quality reduces the need for extra production inventory, improvement DTD time. .改善及维护顺序通过制程 以改进BTS improves and maintains sequence throughout the process, improving Build to schedule (BTS)
42、.,衡量指标-FTT,利益 Benefits 2 .确保接收良品提高品质水准与降低浪费产生並全面提升OEE Increased quality before the constraint ensures that it only receives “good parts” which promotes a higher quality rate and reduces wasted out at the constraint ,which all improve the OEE .以降低索赔（保证），報费，与修理成本改善总成本 Total cost is improved through lo
43、wer warranty, scrap and repair costs,衡量指标-FTT,为什麼 Why:1 改善FTT成果将 improvements in First Through will result in: .提升产能 increased capacity .改善产品品质对内部及外部客户 Improved product quality to internal and external customers .降低大量生产库存结果，改善了DTD时间 Reduced need for excess production inventory resulting in improved
44、Dock to Dock time,衡量指标-FTT,为什么 Why:2 .改善了能力以维护顺序通过制程 改善了BTS improved ability to maintain sequence throughout the process resulting in improved Build Schedule .提升品质 加入作业要求改善OEE increased quality input to constraint operations resulting in improved Overall Equipment Effectiveness .消除因报废，修理，与过多库存浪费 的结果
45、,以改善总成本 Elimination of wastes due to scrap, repair, and excess inventory resulting in improved Total Cost,衡量指标-FTT,何处 Where : .FTT数据收集必须在最终制程實施 FTT Data should be collected at the end of processes .延伸目标：100 percent (100%) FTT 能力 = 零制造不良与交送 Stretch Objective : One hundred percent(100%)FFT capability
46、= Zero defects made or passed on,衡量指标-FTT,何时 When : .首次合格率数據必须收集并使用 .最少以班别（出勤） .数据必须应用带动日常实践行动 .First Time Through data should be collected and used .at minimum by shift . FTT data must drive business practices behavior,衡量指标-FTT,计算说明FTT Formula .这个百分比计算结果 如果所有单件投入一个制程制造 此每件数都通过过程，计算的结果必定100% . This
47、calculation results in a percentage. if every unit entering a process makes it through the process, the result of the calculation would be 100%,衡量指标-FTT,计算说明FTT Formula .驱动使FTT鎖进100% 必须降低报废，返工，重试，退回.或差异在线外修理区，如果这些项目能被降下- FTT将会提升 To move the FTT measurable closer to 100%,the number of units that are
48、scraped, return, retested, returned, or diverted into an off-line repair area must be reduced. If any of these items can be lowered, the FTT will improve,FTT (by operation)单作业 Units entering process-(scrap+returns+repaired off-line+ returns ),投入件数 Units Entering 1000 报废数 Scrap 10 重制数 Reruns 15 重试数 Retest 5 线外修理 Repair Offline 0 FTT%= FTT%= FTT%= 97.0%,Units entering process,1000-(10+15+5+0),1000,970,1000,FTT (by operation) Units entering process-(scrap+returns+repaired off-line