| 2007 LenovoLenovo ConfidentialLean 和 VSM 基本知识介绍Jan 2008 Shanghai Plant DT IE Braver zhao| 2007 LenovoLenovo Confidential项目来源Lean思想的要点 “精益”释义： 精益 - 形容词：无肉或少 肉，少脂肪或无脂肪， 文体或措词简练 反义词： 肥胖的，多肉的 ，过重的，不结实的， 过分 肥胖的，丰满的，粗短的 ，肥大的，软的精益生产： 通过消除企业所有环节上的不增值活动，来达到 降低成本、缩短生产周期和改善质量的目的。Correction 返工Overproduction 过量生产Conveyance 搬运Motion 多余动作Waiting 等待Inventory 库存Processing 过程不当2Placeholder - Presentation title | 6 April, 2006| 2007 LenovoLenovo ConfidentialAgenda 预览 多长时间生产一台? (Takt Time) VSM价值流程图的符号: 简单预览我将不为那个付钱! (时间: VA有价值的, NVA无价值的, Lead) Lead Time vs. Cycle Time vs. Cycle Time 存在敌人: 认识传统的7大浪费/ 新的8大浪费 Kaizen 附件: 基本 LEAN 术语3Placeholder - Presentation title | 6 April, 2006| 2007 LenovoLenovo ConfidentialLenovo Business ChallengesServiceabilityCostQualityNew Product DevelopmentProduct QualityComplexity ReductionSupply Chain OptimizationCompetitionTechnologyForgot my passwordCustomer ExpectationsCant find AC outletHit ! And broken !Tires fingers My OS doesnt boot ! My customer presentation a hour from now !I erased my presentation by mistake!Hung by ESDStill heavy and bigOops, Coffee on keyboard !Diverse Global Workforce4Placeholder - Presentation title | 6 April, 2006| 2007 LenovoLenovo ConfidentialWho Uses Lean Six SigmaCompanies that have implemented Lean Six Sigma have realized savings ranging from 1.2% - 4.5% of revenue. For Lenovo, a 1% savings would represent $130M.5Placeholder - Presentation title | 6 April, 2006| 2007 LenovoLenovo ConfidentialGSC 服务能力, 成本& 质量GSC 挑战6Placeholder - Presentation title | 6 April, 2006| 2007 LenovoLenovo ConfidentialDear Colleague,“In May, I announced Lenovo is implementing Lean Six Sigma (LSS) to identify and address problems and opportunities for continuous improvement throughout the companyLeveraging LSS tools, language and methodologies enables Lenovo to establish a high performance culture, focused on customer value and continuous improvementour current deployment of Lean Six Sigma has been limited to strategic areas of the business. Now, it is time to take it to the next level.I personally invite you to join this important initiative and do your part to continuously improve Lenovo.”Bill Amelio President and CEOA Message From Bill Amelio7Placeholder - Presentation title | 6 April, 2006| 2007 LenovoLenovo ConfidentialLean Six Sigma创造一种文化: 创造客户价值是我们的使命 永不停止的改善是我们的指导原则 追求完美是我们的驱动力 Lean Six Sigma Lean Six Sigma 是我们如何想和做是我们如何想和做Lean Six Sigma Lean Six Sigma 是是 一种方法一种方法, ,工具和语言工具和语言 Lean 是通过减少过程浪费来创造价值 6 Sigma 是通过减少过程的异常来提升质量8Placeholder - Presentation title | 6 April, 2006| 2007 LenovoLenovo ConfidentialLean 成功要素定义价值 价值来源于客户识别价值流 知道,分析,展示并改进 价值流程使流动 识别并消除浪费 使价值最大化过程同步 使所有过程都为客户带来 价值追求完美 持续改进并增加价值Lean 原则1.关注流程. 使用VSA来明确过程,价值和浪费,使过程 可测量并且设定有挑战的改善目标2. 从客户的观点来区分浪费和价值3. 减少浪费通过结构性持续改善包括文化的改变Work with concealed wasteWork with evident wasteWork with added value9Placeholder - Presentation title | 6 April, 2006| 2007 LenovoLenovo ConfidentialHow Lean and Six Sigma Work TogetherLean eliminates any unnecessary steps or waste in the value stream. Six Sigma improves the consistency and accuracy of the remaining steps.LeanSpeedSix SigmaQuality10Placeholder - Presentation title | 6 April, 2006| 2007 LenovoLenovo Confidential关键概念q价值是由客户定义的,为客户定义的 q知道,展示并分析你的价值流程图 q证明在分析你的VSM中你找到了什么是驱动价值 q识别并消除浪费和没有价值的活动 使用VSM和KAIZEN 来消除浪费 同步客户价值和过程 使所有的过程都给客户带来价值 q追求完美 持续改进并为客户增加价值11Placeholder - Presentation title | 6 April, 2006| 2007 LenovoLenovo Confidential附件: 基本LEAN 术语 Value:Value: 价值是由客户定义的,为客户定义的 TaktTakt Time Time 是客户需求的速度,或者多长时间我们客户需要一台产品 Lead TimeLead Time 指的是一个过程中,一件产品从开始加工到结束加工所需要的时间 Cycle Time( Cycle Time( 产品产品) 通过一个加工过程多长时间制造一件产品 Cycle Time( Cycle Time( 员工员工) 员工操作一个动作循环所需要的时间,指每个工位员工操作的节拍 VA = Value AddingVA = Value Adding 该过程改变了最终销售给客户的产品或服务 NVA= Non- Value AddingNVA= Non- Value Adding 这些过程花费了时间,资源,空间,但是并没有为产品或服务增加价值 VSM= Value Stream MappingVSM= Value Stream Mapping 价值流程图,LEAN 体系中强有力的可视化描述流程图的工具 KAIZENKAIZEN = Continuous Improvement 持续改进 D.O.W.N.T.I.M.E.D.O.W.N.T.I.M.E. 8 大浪费12Placeholder - Presentation title | 6 April, 2006| 2007 LenovoLenovo Confidential减少浪费 = 减少Lead TimeCustomerSalesOrder EntryOrder CodingEngineeringOrder CodingMFG DeliverySched- uling13Placeholder - Presentation title | 6 April, 2006| 2007 LenovoLenovo ConfidentialTAKT Time Man你达到了客户的期望吗? ? ? ?14Placeholder - Presentation title | 6 April, 2006| 2007 LenovoLenovo ConfidentialTakt Time: 多长时间我们生产一台电脑? Takt time 是客户需求的速度,或者多长时间我们客户需要一台产品 可提供的工作时间 work time= WT Shift = 8hrs or 480 min WT = 480 min = 28,800s 客户需求Customer Demand = 生产订单Production Order = 3000 units per shift Takt Time = 可提供工作时间 = 28,800s = 9.6s/台 per unit 客户需求 3000 units 为了达到客户的需求, 每9.6S必须有1台主机离开线体15Placeholder - Presentation title | 6 April, 2006| 2007 LenovoLenovo ConfidentialStandard Work3816Placeholder - Presentation title | 6 April, 2006| 2007 LenovoLenovo ConfidentialVSM( Value Stream Mappi