PQPR
PARTNER MERYTORYCZNY NARZĘDZIA: Diana Kidacka
PQPR (ang. Product Quantity Process Routing), jedno z narzędzi lean, które bazuje na założeniu, iż ilość produktu PQ (product quantity) odnosi się do analizy Pareto określającej zasadę 80/20 najlepszych produktów lub usług, zaś routing procesu (ang. PR) odnosi się do analizy części i procesów w celu ustalenia grup produktów. Prawidłowo stworzony PQPR pozwala na zdefiniowanie strumienia wartości i wystarczających danych dotyczących przepływu w procesach, aby rozpocząć projektowanie przepływu ciągłego (ang. One-Piece Flow). PQPR pomaga zaoszczędzić czas na rzecz ulepszeń i ustawić priorytet, dla jakiego produktu lub zakresu produktów należy stworzyć mapę strumienia wartości (ang. Value Stream Map). Strumień wartości można zdefiniować jako wszystkie etapy – zarówno te, generujące wartość dodaną, jak i nieprzynoszące wartości dodanej – wymagane do wyprodukowania produktu lub zrealizowania usługi ze stanu surowego do klienta.
Zmierzając do produkcji opartej o Lean Manufacturing, należy wdrożyć szereg zadań takich jak dokładne zdefiniowanie wartości indywidulanych produktów dla klienta, określenie „value stream”. Wartością produktu lub usługi jest jej zdolność do umożliwienia wytwórcy produktu lub usługi dostarczania wartości swoim klientom, czyli oczekiwanego produktu finalnego. Wartość jest dostarczana za pośrednictwem strumienia wartości (ang. value stream). Jest to kompleksowy proces inicjowany przez klienta oraz jego oczekiwania, który zapewnia dostarczenie wymaganej wartości tak szybko, jak to możliwe. Strumień wartości z kolei składa się ze wszystkich zadań i działań wykorzystywanych do wprowadzenia produktu lub usługi zgodnych z koncepcją klienta i obejmuje wszystkie przepływy: informacji, pracy i materiałów. Przy tworzeniu strumienia wartości dla procesu warto także upewnić się, że zaangażowane osoby dostatecznie rozumieją proces i zachodzące z nim etapy.
Aby uzyskać maksymalne korzyści z działań związanych z mapowaniem strumienia wartości, ważne jest, aby poświęcić należyty czas w celu identyfikowania rodziny produktów, które zamierzamy zweryfikować i ulepszać.
Poniżej przedstawiono przykład realizacji PQPR.
1.Product Quantity
a) wskazanie produktów lub usług sprzedawanych przez firmę w celu generowania przychodów. Mogą to być różne modele produktu, warianty, różne typy usług itp
b) zebranie informacji o wielkości sprzedaży lub przychodach ze sprzedaży każdego produktu z listy.
Jako wyjściową zasadę zaleca się próbę zebrania danych z okresu 6 do 12 miesięcy (PQ)[1]. W niektórych przypadkach możliwe jest też wzięcia pod uwagę prognoz. Niekiedy produkt „najistotniejszy” z punktu widzenia ilości sprzedawanych materiałów będzie inny niż ten, w wyniku sprzedaży którego uzyskuje się najwyższe przychody. W takiej sytuacji decyzję dotyczącą kierunku działań powinno podjąć kierownictwo. Umożliwi to skoncentrowanie się na budowaniu VSM w oparciu o najbardziej krytyczne produkty, które będą miały największy wpływ z punktu widzenia biznesowego na podaż etc. Po przygotowaniu listy produktów wraz z ich wolumenem lub udziałem w przychodach należy zgromadzić informacje o routingu (sekwencji) procesów (pkt. 2).
Tab. 1. Zestawienie sprzedaży i udziału w sprzedaży w PQ [opracowanie własne]
2. Process Routing
Celem zastosowania tego narzędzia jest uzyskanie informacji, w jaki sposób każda rodzina produktów przechodzi przez ten proces. Na przykład, czy niektóre produkty przechodzą przez dokładnie te same maszyny? Jeśli tak, możemy je pogrupować i utworzyć jeden zestaw map strumienia wartości obejmujących oba produkty.
- w tabeli, w której wymienione zostały produkty/usługi należy w poziomie zapisać wszystkie główne funkcje, działania, działy lub procesy, przez które przechodzą. Innymi słowy, wszystkie funkcje lub działy, które są zaangażowane w przetwarzanie produktu lub usługi, aż dotrą one od początku do końca tj. klienta docelowego.
- jak ukazano na rysunku (Rys. 2), należy oznaczyć odpowiednie procesy przez który przechodzi dany produkt, symbolem „x”. Chociaż w poniższej tabeli założono tylko 10, w rzeczywistości na tej liście mogą znajdować się setki produktów. Nietrudno zaobserwować można, iż produkt 1 i produkt 4 mają podobne procesy. To podobieństwo sprowadza je więc do pojedynczej grupy. Podobnie, produkt 5 i produkt 8 można przypisać do tej samej grupy, ponieważ mają one podobne przebiegi procesowe.
Tab. 2. Zestawienie sprzedaży i udziału w sprzedaży – część PR [opracowanie własne]
- następnie w oparciu o powyższą tabelę, należy nadać priorytet produktowi lub grupie produktów, dla których chcielibyśmy rozpocząć budowanie VSM. Może to być produkt o najwyższej sprzedaży lub o najwyższym dochodzie lub produkt, który napotyka najwięcej problemów w sekwencji procesów.
Kombinacja dwóch narzędzi stanowi PQPR. W tab. 3 zaobserwować można największą produkcję i sprzedaż produktu X, natomiast największy przychód generuje sprzedaż produktu B.
Następnie na podstawie sekwencji procesów można stwierdzić, że X oraz A przechodzą przez te same etapy produkcji. Ponadto produkt A stanowił drugie miejsce pod kątem zarówno sprzedaży, jak i liczby wysłanych jednostek. Tak więc w tym przykładzie najwłaściwszym byłoby wspólne odwzorowanie produktu X i Z.
Tab. 3. Zestawienie sprzedaży i udziału w sprzedaży w PQ [opracowanie własne]
Jeśli Twoja organizacja oferuje jakiekolwiek produkty lub usługi o małej wielkości i dużej różnorodności, najważniejszym sposobem zgodnym z zasadami lean w celu minimalizacji problemów wynikających z dużej zmienności jest segregacja produktów w odpowiednie grupy (rodziny) produktów. Jest to istotne dla efektywnego zarządzania całkowitym zapotrzebowaniem dla grupy, maksymalizując przepływ (flow[2]) do odpowiedniego poziomu, zgodnie z ideą lean.
Całkowite zapotrzebowanie na rodzinę produktów jest znacznie bardziej przewidywalne i łatwiejsze do kontrolowania niż zapotrzebowanie na każdy produkt lub usługę.
Nie jest przesadą stwierdzenie, że szczupłe zarządzanie tak różnorodnymi produktami jest po prostu niemożliwe bez dobrze przemyślanych grup produktów.
Tworząc grupy produktów, należy, analogicznie do powyższych założeń), rozpisać wszystkie materiały/usługi np. w wierszach, zawierając elementy prowadzące do powstania finalnego produktu (Rys. 4). Następnie w kolumnach można wpisać procesy. Oprócz procesów i maszyn można również użyć dodatkowych kolumn dla wszystkich innych czynników, które wyróżniają linie produktów (z perspektywy operacji). Wskazane może być formatowanie komórek w celu identyfikacji procesów wchodzących w skład dzielonego centrum, gdyż podczas grupowania podobnych produktów często poszukuje się możliwości segregacji podobnych procesów mogących w bliskim czasie być przeprowadzone w urządzeniach/maszynach dedykowanych do tej właśnie grupy. Dla każdego procesu stosowanego do dostarczenia danego produktu lub usługi, należy zaznaczyć komórkę symbolem X oraz opcjonalnie np. A, A’ dla procesu alternatywnego. Poprzez przeniesienie wierszy w celu pogrupowania podobnych produktów, uzyskujemy informację o tym, co rodzina produktów oznacza w danej firmie.
Zwykle rodzina produktów składa się z produktów i usług, które są na tyle podobne, że do celów planowania można je traktować jako pojedynczy produkt.
W przypadku, gdy całkowity czas procesu dla produktów może wynieść więcej niż 30% średniego czasu dla wszystkich produktów/usług w danej linii, warto
Proces, który zajmuje więcej niż 30% średniej, może wymagać specjalnej uwagi w celu zidentyfikowania tych, których wyprodukowanie zajmuje znacznie więcej czasu. Warto wówczas zanalizować je osobno, aby móc zweryfikować słuszność przeniesienia ich do innej grupy produktów lub zaplanować ich wytwarzanie przy użyciu specjalnych technik.
Tab. 4. Matryca grup produktów dla linii produkcyjnej [opracowano na podstawie 2]
Prawidłowo stworzony PQPR pozwala na zdefiniowanie strumienia wartości i wystarczających danych dotyczących przepływu w procesach. W praktyce procesy, a tym samym analizy mogą będą znacznie bardziej skomplikowane niż scenariusze przedstawione w opracowaniu. Przyjęta metodyka tworzenia PQPR nie powinna się jednak znacznie różnić. Proces ten działa również w środowisku biurowym. Zamiast weryfikować na maszyny, urządzenia możemy obserwować np. „przepływ” dokumentacji przez biuro.
Bibliografia
[1] Anupindi, Ravi, Sunil Chopra, Sudhakar D. Deshmukh, Jan A. Van Mieghem, and Eitan Zemel. Managing Process Business Flows. 2nd ed. Upper Saddle River, NJ: Pearson Prentice Hall, 2006
[2] Finch, Byron. Operations Now. 2nd ed. Boston: McGraw-Hill Irwin, 2006
Netografia
[3] How to Create a Product Quantity / Product Routing Matrix, dostęp online pod adresem: https://blog.gembaacademy.com/2008/02/12/how-to-create-a-product-quantity-product-routing-matrix, [dostęp 25.09.2018 r.]
[4] Pre-requisites for Creating Value Stream Map, dostęp online pod adresem: http://www.leanforu.com/pre-requisites-for-creating-value-stream-map/, [dostęp 25.09.2018 r.]
[5] Product Family Matrix; dostęp online pod adresem: https://www.systems2win.com/solutions/product-family-matrix.htm, [dostęp 26.09.2018 r.]
[6] Product Quantity Process Routing (PQPR), dostęp online pod adresem: https://enna.com/dictionary/product-quantity-process-routing-pqpr, [dostęp 25.09.2018 r.]
[7] Value Stream Mapping overview, dostęp online pod adresem: https://blog.gembaacademy.com/2008/02/08/value-stream-mapping-overview/, [dostęp 26.09.2018 r.]
Przypisy
[1] How to create a product quantity – product routing matrix [3]
[2] flow (ang. przepływ) – przepływ procesów, czynności; działania muszą następować po sobie z minimalnymi przerwami i minimalnymi zapasami pośrednimi
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