Application And Research Of The Value Stream At JDS Plant

Value stream is a powerful tool which introduces and implement the lean philosophy and is the important part of five principles. Production behavior includes three kinds of activities---value-added,non-value-added and waste. Customers define whether the activity is valued or not. Connect all the valued activities like a stream , which is called value stream. Production activity is divided into four kinds. The first is low mix and discrete. The second is high mix and discrete. The third is very high mix and high customization. The fourth is low mix and high customization. Value stream analyses is suitable for the first and second production mode. JDS production line includes the first and second mode, so JDS should regard the method of value stream as a powerful tool.Value stream process consists of three steps.The first step: create the current value stream map.At first, we should define the right products families. According to if the products process is similar, we analysis the products that pass through the assembly line, fixed outer race line, DO outer race line, inner race line, cage line and shaft line, and we find that exclude VL outer race and VL inner race is very different to DO outer race or other inner race, other products group can consider as each products family. Identify if a group of similar products is a products family, another rule is that: the total work content of the downstream process steps for each part in the product family should be within 30 percent of each other. After calculate we find all work content pass through each line is within 30 percent of each other, therefore we can accept the product family definition before.Then we will create the current value stream map. We should know the customer information above all: who are our customers, how much is the demand per month or per day, what is the shipping batch, how many are there in each package, how often we should delivery? After get them, we draw these information on the map. The continue things is got the similar information about suppliers and draw them on the map. Follow thing is draw JDS information, it include cycle time, changeover time, uptime, process time and works in process in every procees. At last, we got the lead time is about 25 days and process time is about 200 minutes.The second step: analyze in details, create the future value stream map.We should analyze current value stream map and divide the whole process into loop related to decrease the complexity. After analysis we got the frame like that: building a supermarket for finish goods so that it can absorb the variety from the customer, and through fulfill the lack of super market pull the assembly cell production, the demand of assembly pull finish parts supermarket, through fulfill the lack of parts supermarket pull parts making lines. Since the supplier can't shipping every day, we have to build supermarket for material. giving assembly cell, cage cell and fixed outer race as example, we identify each detail parameter.At first we identified assembly cell Takt time is 39.5 seconds, then got assembly interval is 1 day, made the operator balance chart for the product and the product family, created standard work document, identified the pitch is 48 halfshaft for 95 family in pacemaker and 90 halfshaft for 75 family, and time frame is 27 minutes and 57 minutes. Then we scheduled the mix at the pacemaker, gave the project to deal with changes in customer demand.Identify the detail data for cage cell and fixed outer race cell ,employ similar steps as assembly cell.Follow identify Leveling and Scheduling and Finished Goods Stategy, Pull through Suppliers Stategy, at last integrate all information create the future value stream map.The third step :implement the future value stream map. We should take a lot of KAIZEN event to support the future map.