5.4 standard operations

8/2/2019 5.4 Standard Operations

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Kaizen

Standard Operations


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n r i r i n

Operationssafelycarriedoutwithalltasksorganisedinthebestknownsequenceandbyusingthemosteffectivecombination

of

resources.

Resources

, , ,Conditions

Consistent and repeated operations

Operations adjusted for human ease andeffectiveness

Equipment and resources well maintained


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Std Ops eliminate human work waste to...

...ensure the effectiveness and increase the efficiency

Effectiveness:

obtain the desired results

Efficiency:

obtain the results in an "economical" manner


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Standard Work Objective

Eliminate waste related to

the flow of material

machine work and human work

Thisis

the

objective

of


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Waste from no standardisation

Deviations and Proliferations

50recipe

documented

50 results Quality the(deviations) rs me

(no variation)


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Document human work

omp e e Simple

Visual

Document the line Document the operators work

Document the operations:* work sequence, work contents (safetynotices, quality norms, etc.)

= a unique recipe

= a training tool= an improvement tool


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Constructing a Std Op

1. ANALYSE THE JOB (OPERATIONANALYSIS):-

5. IDENTIFY THE KEY POINTS:-For each Main Step, write in the subtle

- -blow account of the activities performed;manual, visual, mental etc., including all

steps necessary to guarantee quality,efficienc and safet . If there are different

tr c s o t e o w c ensure t atquality, safety and efficiencyrequirements are met.

way of doing the job, all are analysed.

2. IMPROVE TO GENERATE THE BESTCURRENT METHOD:-Think over these ste s:

. :-Try out the method again, just followingthe Main Steps and Key Points to besure that they are, by themselves,

- How can the job be made easier or quicker.- How can we make it difficult to get wrong(Quality and Safety).Then write in any improvements.

.

Correct any errors or sections left out.

7. COMPLETION:-

3. CONFIRM THE METHOD (A):-Try out the improved method, to check that it

is quicker/easier and that quality standards

helpful or necessary and details such astooling, tolerances, protective clothing,training notes, etc.

.out.

4. DIVIDE INTO MAIN STEPS:-Summarise and write the main stages of thejob.

Describe each stage or Main step in a briefand straightforward way; What you do, towhat? with what?


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Wh Standardised O erations ?

.

Visually provide useful information for the.

Promotes ownership by being drawn up bysho floor eo le.

Promotes root cause problem solving directly onthe shop floor.


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Three Elements of Standard Work

Cycle timeWIP

WIPWIP

WIP

Standard work in Sequenceof work

WIP

Finished goods

Cycle time


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Determine the standard work-in-process

Minimum quantityof parts in-process for acontinuous low o operations

ea y: par per s ep o e process

Reality: optimal batch based onreject forecastmachine stoppage forecastrhythmical machine capacity (flow)

set-up timeetc.


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Calculate the standard work-in process

OP 10 OP 20 OP 30 OP 40

10ACTUAL 10 10 1053 1 1 10 1

OBJECTIVE0 5 5 0

0 0 0 04 1 1 11


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STANDARD WORK IN PROGRESS

OP OP OP OP OP OP OP OP OP OP OP OP

Objective

Ideal


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Information Content

METHODOperation flow chart

MATERIAL

Part numbers

LocationsStock in rocess

EQUIPMENT

Equipment identificationLocation

TOOLING Tool identificationDescription

Quality check operationsCare points

Safet o erations

TIME

Safety devices to be used

Customer cycle timeProcess C cle time


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Standard Operation Sheet

STANDARD OPERATION SHEET

SUPPOR WELD

GET SUPPORT PLATE

T PLATE M/CREINFORC

EMENTPLATE

M/C, GET NUT, PLACE INWELD M/C. GET ASSY.

WELDM/C

PLATE

PLACE ASSY & REINF. IN

FIXTURE

SPOT WELD (2)

WIP

WIP CUST CYCLE CELL CYCLE SAFETY CHECK

WEAR SAFETY

UNCLAMP, LIFT OUT ASSYPUT IN CONTAINER.RETURN TO START


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Wheel Change Exercise


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Wheel Change

. pen oo an o a n ac .

2. Jack up car.

3. Obtain brace from boot.

. mu aneous y owheel in place with LH.

11. and start nuts on studs4. Remove hubcap with brace

end.with RH.

12. Tighten nuts with brace..

aside.6. Remove wheel and place in

. ep ace u cap.

14. Lower jack and removefrom car..

7. Unclip spare wheel retainer.

8. Life out spare and place on

15. Replace brace in boot.

16. Place wheel in well andu .9. Pick up wheel nuts in RH.

c p re a ner.

17. Close boot.


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IDENTIFY THE KEY POINTS:- NO: MAIN STEPS1. Open drivers door,check handbrake is fully engaged by lifting lever.2. Lift boot lock lever until is felt to open.3. Walk to boot and open lid.

1 ENSURE HANDBRAKE IS ON

PRESS SPARE TO ENSURE4. Press spare wheel hard to confirm it is inflated.5. Unclip wheel retainer.6. Lay wheel flat on boot floor and load jack and brace.7. Lift out wheel, carry to wheel arch, squat and lay wheel on ground right

INFLATEDCARRY TOOLS TO WHEEL

.

8. Use flat end of brace lever to prise off hub cap, aside hub cap, concavesurface up.

9. Slacken wheel nuts off 2 full turnswith brace, aside brace.10. En a e to end of ack to nearest ackin oint, ensure lower end is on

2 SLACKEN NUTS TWO TURNSBEFORE RAISING CAR

ENGAGE JACK AS ILLUSTRATEDflat surface and jack is vertical.

11. Turn jack handle clockwise until wheel is about 2clear of ground.12. Pick up brace and place nuts in hub cap.13. Aside brace andplace nuts in hub cap.

AT NEAREST POINT

RAISE WHEEL 2 CLEAR OFGROUND

14. s ng ot an s, t w ee o stu s an rest aga nst pane to e t o

wheel arch. PLACE NUTS IN HUBCAP15. PU spare wheel, align with studs and place on hub.16. Holding wheel on hub RH, LH pick up nuts and start on threads top first, then

3 USE BOTH HANDS TO FIT NUTS

, .

17. Simultaneously LH fit remaining nuts, RH. PU brace and run nuts to hub insequence shown. Leave brace on final nut.

18. Turn jack handle anti clockwise to lower car. Remove jack.

19. Using both handsfully tighten all nuts in reverse sequence (4 3 2 1).

HUB

TIGHTEN IN SEQUENCE

ILLUSTRATED

20. PU jack, walk to boot and aside jack and brace.21. Walk back, PU hub cap and centralise over retaining clipson wheel. Push home

firmly confirming OK condition by click of clips and even gap between hub cap

4 CENTRALISE CAP OVER CLIPSBEFORE PUSHING ON

and wheel profile.

22. PU spare wheel, carry to boot and place in wheel well.23. Clip spare wheel retainer in place; close boot.

CLIP SPARE IN WHEEL WELL

5.4 standard operations

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