Transcript Lean Event Overview

The Fundamentals Of
Standard Work
Quick Review
Standard Work Is:
• The best combination of people and equipment,
• Utilizing the minimum amount of labor, space,
inventory, and equipment,
• For a specific level of customer demand
The way we choreograph the operators within a process for a given
level of demand (takt time)
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Standard Work
Standardization …
• Reduces Variation
• Enables Flow
• Eliminates Waste
• Fuels Continuous Improvement
... in quest of the:
shortest lead-time
highest quality
lowest cost
Standard Work is part of the foundation
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Why Implement Standard Work
• To make it possible to identify and eliminate variations in
operator work
• To sustain the gains achieved from improvement
activities
• To provide a baseline for future improvement
Standard work and variation reduction are key
in creating a foundation of stability.
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How Leaders Support Standard Work
•
Ensure that SW is Documented for Each Operator
• Ensure that SW Documentation is Displayed
• Ensure that all operators are trained and follow
agreed upon SW
• Encourage Experimentation and revisions to SW
after improvements are found
• Repeat above cycle
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Applying Standard Work
• Team Leaders determine the SW work goal (shared by
work team).
• Everyone seeks to improve against the standard focusing
on identifying and eliminating waste
• Each process in the flow becomes the customer of the
preceding process.
• Each preceding process becomes a just-in-time supplier
for the consuming process (RM towards FG).
• Operational tests, Quality checks, 5S actions, and
material conveyance are included in SW.
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Essentials of Standard Work
• Standard Work Is:
• Created by people doing the work, facilitated by their leader.
• Operator Specific
• Specifies content, sequence, timing, and outcome.
• Includes Takt time and Standard Work-in-Process (SWIP)
inventory.
• Clear, visible, and posted at the process.
• Defines the normal condition; normal is not chaotic.
• Only changed based on Takt or improvement by the owners.
Standard Work always enables production.
The standard is the specification for evaluating potential
improvements.
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The Path To Standard Work
Takt Time
• Available time
• Customer demand
Work
Content &
Sequence
Line
Balance
• Time Observation Form • Load Chart
• Total work content
• Balance work
• Enable flow
• Required resources
• SW Combination Sheet
• Content
• Sequence
• Timing
• Outcome
• Safety
Standard
WIP
• Location
• Amount
• Enable Flow
Standard Work
Standard Work is central to the Continuous Improvement Process
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Capturing Work Content
Step
Description
Time
Notes / Improvement Ideas
Process:
Step Op Element
1
2
3
4
5
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7
Observer:
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Date:
Task Time Remarks
Time for 1 cycle
Activity of the Product
Multi-Cycle Analysis
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1
Time
Takt
Time
Total Manual Workload
= Manpower
Takt Time
Op A
Op B
Op C
Op D
Line Balancing
Op E
Op F
Staffing
Activity of… analysis, line balancing and staffing calculations all
come together as inputs to Standardized Work
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Standardized Work Combination Sheet
Pulls it all together…..
• Takt Time
• Work Content and Sequence
• Line Balancing
• Standard WIP
Specifying…….
• Flow of human work within a process
• Time requirement for each work element
• Work content contained within the Takt time
Helping…..
• Identify improvement opportunities
• Balance human motion and machine operations
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Example: Standardized Work Combination Sheet
Standardized Work
Combination Sheet
Hr/
day
Revision Date:
Revision #
Sec/day
Takt
Total
Labor time time
Walk Time:
Manual:
Manual Time:
Head
Count
Cycle
time
Automatic:
Labor Value Added Time:
Walking:
Machine Time:
Basic Time Requirements Hrly output
manual machine walk
time auto time time
sec. seconds seconds 1
S
t
e
Element
p
1
Pick up RM
2 Un/re-load start M1
3 Un/re-load start M2
4 Un/re-load start M3
5 Gauge shaft OD
6 Put down FG
2
6
6
5
7
2
21
24
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TT
Operations Times Denote Cycle / takt time with a bright marker
User Defined Intervals
5
10
15
20
25
30
35
2
2
2
2
2
2
Standardized Work combination sheet specifies all elements of
work content, time and work flow
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The Fundamentals Of
Standard Work
Quick Review