精益价值流培训资料LeanTrainingtoSee.ppt

Lean implementation steps - SCL approach Layout changes Loss elimination through TPM Step 2 : Create flow Step 3 : Balance to takt time Step 4 : Stabilise the Production Step 5 : Improve flow Step 6 : Zero defect Step 7 : Levelled production Step 1 : Value stream mapping STEPS MEASURES Process ratio in percentage Single piece flow Ratio between cell bottleneck time and takt time OLE of the cell Percentage of missed cards per shift PPM Every part every day/ Every shift/Every hour Paced withdrawal, PULL system Match the pace of production to the pace of sales Layout changes Loss elimination through TPM Mapping the process flow for a product / product family Step 1 Value stream Processing time Original state 1 Shipping Assembly Plating Machining Stores Production Control C/T=30s CO=0 Uptime=100% 2 shifts 64800s CO=0 Uptime=98.5% 2 shifts 10 stations C/T=120s CO=0 Uptime=100% 2 shifts 7 stations C/T=238.2s C/T=295s Uptime=46% CO=0 2 shifts 14 stations C/T=30s CO=0 Uptime=100% 2 shifts 64800s C/T=300s CO=0 Uptime=100% 2 shifts 64800s Daily Despatch plan Daily plan Monthly/Weekly Fax Month/weekly/daily plan Inspection 1(shared) 2(shared) 2 2(shared) 5 1(shared) Packing 1X Daily/weekly 1X daily Supplier SCL-Foundry Supplier 1X daily I I I I I I 468 227 183 25 124 7 Prod.lead time 300s 30s 1610s 570s 514s 30s 1 day 1.135 day 0.915 day 0.125 day 0.62 day 0.035 day Customer Value added Time Production lead time 3054s 67392s = Process Ratio = 4.53% Demand/month Telco - 8500nos. AL - 1500nos. 200 nos. shift Demand/month 10000 Marketing Daily plan Monthly schedule Takt time 130 Sec. Cycle time 238.2 secs Cycle time 295 secs Uptime 46% Date - 16.03.2000 Step 1 Value stream 717s 0.2 day Value added time Production lead time 1610s 8100s 0.12 day 0.12 day Shipping Assembly Plating Machining Production Control MRP C/T=119s CO=0 Uptime=100% 2 shifts 7 stations C/T=180s CO=0 Uptime=100% 2 shifts 7 stations C/T = 95s CO=0 Uptime=94.5% 2 shifts 19 stations Mktg Daily Da