价值流程图分析及衡量指标

衡量指标－DTD
• 为什么Why 衡量生产库存周转的时间管理 *DTD生产库存周转的时间管理 DTD日程越短则周期越快 有效管理库存资金降低生产总成本 快速对应客户需求
衡量指标－DTD
• 为什么Why DTD附加价值（实质）作业 （Value added operation)仅仅少部分 DTD绝大部分时间是无附加价值的 -等待(wait) 停滞(stagnation) -缓冲(Buffer) 库存(Storage) -搬运(Transfer) -检查(Inspection) -返工(Rework)
Units entering process
衡量指标－FTT
• 定义 Definition2 *FTT是衡量生产制程的品质
It is a measure of the quality of the manufacture process
*可应用FPS程序工具改善FTT （防错措施、目视化工场、快速转换）
• 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 排除嫁动损失，提高总合成设备效率 善用价值流程图
衡量指标－DTD
• 降低总DTD时间 DTD－从价值流图析能作明确有效展现 应用工业工程分析改善效率 进行时间缩短的改善 时间－是各个企业公司同样拥有的唯一等量资源
*以降低索赔(保证)，报废与修理成本改善总成本
衡量指标－FTT
• 为什么Why:1 *改善FTT成果将：
Improvements in First Time Through will result in:
*提升产能 Increased Capacity *正对内部以及外部客户改善产品品质 *降低过量生产库存以改善DTD时间
衡量指标－DTD
DTD进料仓库到出货仓库的时间
进料 仓库 出货 仓库
生产制造过程
制造周期时间－MCT
进料
出货
进料仓库到出货仓库时间－DTD
衡量指标－DTD
• DTD－进料仓库到出货仓库的时间 指原材料进场到制完成品准备出货时间 包含制造周期时间 • DTD－是衡量物料通过工厂的速度， 不仅仅是制程的速度 DTD is measure(in hours) of the speed of material through the plant, not the speed of the processes.
（一）
精益推展 衡量指标
精实生产衡量指标 Lean Manufacture Measurable’s • 进料仓库到出货仓库的时间－DTD （Dock to Dock） • 首次合格率－FTT （First time OK through） • 依排成生产－BTS (Build to shecdule) • 总合设备效率－OEE (Overall Equipment effectiveness)
Increased process/ output quality reduces the need for extra prodution inventory, improving DTD time. improves and maintains sequence throughout the process; improveing Build to Schedule(BTS).
衡量指标－FTT
• FTT 首次合格率
投入制程总件数 返工+重测 线外修理+退回件数 （报废+返工 重测 线外修理 退回件数） 报废 返工 重测+线外修理 退回件数） 投入制程总件数
Units entering process-(scrap+reruns+retests+repaired off-line+returns)
衡量指标－DTD
• 如何做 降低原材料库存 降低安全库存 提高进料频度
衡量指标－DTD
• 如何做 降低成品库存 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 防错措施 *单件流 小批量 *作业依排序生产 *推进全员生产性保养 *缩短转换时间
衡量指标－DTD
• 为什么Why:2 *通过提高生产过程顺序生产能力改善了BTS性能 Improved ablity to maintain sequence throughout the process resulting in improve Build to Schedule *提升品质输入以保证操作从而改善OEE Increased quality input to constraint operations resulting in improved Overall Equipment Effectiveness *消除因报废、修理与过多库存的浪费结果总成本提高 Elimination of waste due to scrap, repair, and excess inventory rusulting in improved Total cost
衡量指标－DTD
• 总合DTD计算: 单作业 DTD=总管制数 / 线末速率 复合作业 （DTD作业1+ DTD作业2+ DTD作业3） DTD= 线末速率
计算作业实例
计算作业实例
计算作业实例
首次合格率 First Time Through
衡量指标－FTT
• 定义Definition1 *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 *不含被报废、返工、重测、线外修理，退回件数 First Time Through is the percentage of units that complete a process and meet quality guideline. The first time without being scrapped, return, retested, repaired, or returned.
衡量指标－DTD
• 何处Where:2 *制程工作，包含物料在修理返工区域 以及全部缓冲区 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件并入 DTD计算直到被从码头交运 Finished Goods End Item Products – All finished goods containing the control part are include in the DTD caculation until they are physically shipped from the dock
衡量指标－DTD
• Benefits利益 • DTD时间改善通过减少在线物料以及物料的库存总量。这就减少 了损坏机会从而也提高了FTT Dock to Dock time is improved by decreasing inventories which leads to less material handling and storage. This results infewer opportunities to damage parts, there by improve 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 dilivery (OTD) target • 减少物料管理、废弃以及库存搬运成本，全都可以改善总成本数 Lower material handing, obsolescence, and inventory carrying costs, all lead to improved Total Cost 处Where:1 * 原材料－购买的零件（管制部件） 接收进入工厂开始计数，其中包括连委制件， 因为这些已经进为产品构成 Raw material– Pruchased Part(control part)Begin counting when it is received in the plant, Even on consignment , because it is already in its product form. *原材料变更为产品构成 Raw material that it changed to its product form
DTD-Dock to Dock Time
进料到出货时间
Dock to Dock time(DTD) • Definition 定义 从原材料下货到完称品出货之间的过去时间 The elapsed time between the unloading of raw material and the release of finished goods for shipment. • 总DTD时间为产品消耗时间，如原材料、制程作业、 与在厂完称品出货前存在品的时间。 The total Dock to Dock time for a product includes the time that a product spends as raw material, workin process and as a finished product in the plant, prior to being released.
衡量指标－DTD
• 为什么Why • 工厂必须消除浪费并转变成顾客方向拉动式系统 Plant must eliminate waste and move toward customer “Pull” systems. • 设置巨大缓冲区生产过多零件（增快制程速度）但是降缓了物料 速度 By building large buffers you product more parts(increase the speed of your process) but slow down the speed of materials. • 减少库存可以减少物料管理以及存储、损坏零件机会较少 Decreaseing in ventories leads to less material handling and storage, which results in fewer opportunities to damage parts
衡量指标－FTT
• 利益 Benefits 2 *确保仅接受良品,这就提高品质水准与降低生产 浪费全面以提升OEE
Increased quality before the constraint ensure that it only receives “good parts”, which promotes a higher qulity rate and reduce wasted output at the constraint, which all improve the OEE. Total Cost is improved through lower warranty,scrap and repair costs.
衡量指标－DTD
• 何时When: 数据收集工作必须在一个作业型态能充分表现 生产线优良表现的同一时段内收集 Data should be colected at the same time which best represents the operating pattern of product line.
We can improve our FTT by applying our FPS process and tools(error-proofing, visual factory& quick changeover).
衡量指标－FTT
• 利益 Benefits 1 *提升制程产出品质降低大量生产库存需求，改善 DTD时间 *改善以及维护顺序通过制程改善BTS
Improved product quality to internal and external customers Reduced need for excess production inventory resulting in improved Dock to Dock time
衡量指标－FTT