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Standardized Work

Creating Continuous Flow

Presented by:

Brian D Krichbaum

Process

Coaching

Incorporated

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Standardized Work

Definition

A detailed and documented system in which

production workers both develop and follow arepeatable sequence of tasks within a work

assignment. The standardized work sequence

represents the best practices for the operator to

follow in the completion of his/her job.

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Takt timeDemand RateCycle TimeProduction Time

Work Sequence

Standardized Work

Elements

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Takt Time - the demand rate of production, the

rate at which we sell our product or service.

Takt is a German musical term which refers to

the pace, or drumbeat of a musical score. The

concept of takt keeps our activities on pace

much as the metronome keeps the musician onthe beat.

Standardized Work

Takt Time

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Process Instruction SheetsStandardized Work Analysis Sheet (Cell Layout)

Time Observation Sheet

Operator Balance Chart

Standard Work Combination Sheet

Standardized Work

The Tools

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Standardized Work

Process Instruction Sheets

Definition

Detailed, visual instructions written from theperspective of the operator which detail the

sequence, methods, tools required and critical

to quality characteristics of an operation.

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Definition

Detailed, visual representation of the location of

everything in the workcell, includingworkstations, parts racks and storage areas,

and operators.

Used to plan the layout of cells, analyze the

amount of walking built into the process and toinstitutionalize improvements

Standardized Work

Cell Layout

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Work Instructions

Obtain Full Box of Blocks

Empty BoxPlace Blocks on Table Remove 1 blue label from each block

Remove 1 yellow label from each block

Remove 1 red label from each block

Repack Box

Return to storage area

Standardized Work

Time Observation Exercise

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REMARKS

1 2 3 4 5 6 7 8 9 10 11 12

Time for each

Component

Running Time

(cumulative)Total

Time

Task Component

Observation Number Assigned ComponentTime

Time For One Cycle

Task/Process Being Observed Observer(s) Day/Time Of Observation

Step No.

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Standardized Work

Operator Balance ChartsDefini t ion

A graphical representation of the times

required by each operator in a cell tocomplete their individual work elements.

Operator balance charts are used to

distribute work and ensure work is being

completed near takt.

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Standardized Work Combination SheetPart Number

Part Name

Work Sequence

Operation Time (seconds)

Man Auto W alk 5 Sec 10 Sec 15 Sec 20 Sec 25 Sec 30 Sec 35 Sec 40 Sec 45 Sec 50 Sec 55 Sec 60 Sec 65 Sec 70 Sec 75 Sec 80 Sec 85 Sec 90 Sec 95 Sec100 Sec105 Sec110 Sec115 Sec120 Sec

1

Obtain Manifold from

conveyor 15 5

2 Place in Wash Tub 10 1

3

Press Button to start wash

tub 1

4 Wash Tub Cycle 10 10

5

Obtain Manifold from

wash tub 6

6

Place manifold on work

bench 2 5

7

Obtain 4 valves from

stock area 2 5

8

Remove packaging from

valves 10

9 Place valves on manifold 8

10

Obtain screws and hand

tighten 7

11

Obtain torque wrench and

torgue to 50 ft lbs 3

12

Record torque values on

tracker 8

13 Mask off valve assembly 9

14Aside to pallet 4

15

Move to conveyor to start

next assembly 5

95 10 21

Date Prepared 10-Mar-05 Daily Demand

Step Operation

Time

231 Units

HT Injection Manifold Work Area Manifold Assembly Takt Time 117 Second

98-097-654

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Standardized Work

Equipment Guidelines Before investing in more equipment:

Eliminate waste in the machine cycle

Split apart tasks at the bottlenecks; use

more than one machine

Install multiple machines at thebottlenecks

Create another cell

When there are no other choices, operate thebottleneck in a decoupled manner (batch, notflow)

8. Ibid - page 63