劳斯莱斯精益案例.pptVIP

Exercise: ABC Forging (Sample Data) Brainstorm Future State 2-yr forecast Sub- Tier 8-Week Order to Deliver Volume Mix Delivery Quality Response 2-yr forecast 60-Day Schedule = 1750/yr 5/5/5/1.5/1 = 75% = 15k cppm = 5 days Production Control SAP Rolls- Royce Release Material Daily Priority Lists Release Weekly 200 mi Weekly 4 weeks 20% ↓ 5% Rework 2 weeks Saw C/T=15 m C/O= 20 m Batch= 40 Forge C/T=7 m C/O=1.5 h Heat=2 h 150 mi Heat Treat C/T = 9 h Cool= 8 h Insp C/T=3 m 150 mi Mach ine C/T = 3 h C/O = 2 h Insp C/T = 1.5 h Pack C/T= 5 m 0:15 5 Days 2:10 17 Days 17:00 2 Days 0:03 14 Days 3:00 7 Days 2:00 3 Days 0:05 Cycle Time = 24 hrs Transport = 6 hrs Idle= 48 days Value Stream Mapping Value Steam Mapping The Value Stream - a definition “All of the steps required to bring a product or service from raw state through to the customer” Total Value Stream Supplier Process C Process B Process A Customer Internal Plant 2 Value Steam Mapping What is Value Stream Mapping? Value Stream Mapping is a powerful technique that allows us to create a “BIG PICTURE” visual representation of: – All the steps in the process, working back from customer demand to raw material – The flow of both material and information and the effect they have on each other – The distinction between value-added and non-value- added activity (WASTE) – The effect all of the above have on meeting the customer’s requirements 3 Value Steam Mapping The 8 Wastes Scrap/Rework Over-production Inventory Motion Processing Transportation Under-utilized People Waiting (manpower, material, machine) 4 Value Steam Mapping #1 Scrap/Rework Definition: – Any product that does not meet specifications and therefore either needs to be reworked or scrapped Goal: – 100% First Time Through Quality 5 Value Steam Mapping #2 Over-production (Under) Definition: – Producing mo