Work Measurment CaseStudy

Texas Center for Applied Technology
Work Measurement and Process at a

Glance in Lean
(A case study at the Corpus Christi Army
Depot by Texas A&M Engineering)
Harry S. Whiting II, MSIE
Fred Canales, BSIE
Dr. J. J. Congleton, PhD, CPE, PE
1 - TEES/CCAD Proprietary Information

Lean Process
• Preparation for Lean Event

• Value Stream Analysis
• Prep work for process analysis
• Lean Event
• Verify correct process
• Eliminate NVA steps
• Future State
• Process At A Glance
• Run the new process to verify
• Implement 2 - TEES/CCAD Proprietary Information
Lean Process (Preparation)
• Value Stream Analysis

• Value Stream Map w/ areas of opportunity
• TAKT Time calculations
• Prep work for process analysis
• Observe and record process
• Create Process Map
• Layout & Spaghetti Chart
• Sort data (VA, NVA, NVAN, Wastes)

TAKT Time
• TAKT is a German word meaning Beat

• Producing to the pace of customer demand (no
faster, no slower).
• TAKT time = Available time/Customer
Demand

Calculating TAKT Time
Typical TAKT Time Calculation:

991 units = 82.5 units per month
12 months
82.5 = 4.12 units per day = 4 units per day
20 days/month
15 Hrs (2 Shifts) = 3.63 TAKT Time

4.12

Identify Problem Areas
Observation Time vs. TAKT Time
8
7.32
7
6
5.41
5
3 TAKT 3.63
0
OBSERV. # 1 OBSERV. # 2

Observe process
Time observations on the shop floor

Time Observation
• Best way to see waste.

• Real facts and data about the operation.
• Non-Value added waste is seen in detail.

Std Work Combination Sheet
New / Revison ________ Page _______ of _______ Date _____________ Standard Work Combination Sheet
Organization Work Center Supervisor Operator Product Line Part Number Part Name
Time 2 Customer Demand units Available Time units Takt Time

Secs. Min. Hours Days mins. mins.
Step
* Start Value Added Non-Value Added sub-total
# Process Description
time/date for ref.
manual auto manual travel queue 0 Start
VANVA 20 time 40 60 80 100 120 140 160 180 200 220
(see notes)
1 0 0
2 0 0.0
3 0 0.0
4 0 0.0
5 0 0.0
6 0 0.0
7 0 0.0
8 0 0.0
9 0 0.0
10 0 0.0
11 0 0.0
12 0 0.0
13 0 0.0
14 0 0.0
15 0 0.0
16 0 0.0
17 0 0.0
18 0 0.0
19 0 0.0
20 0 0.0
Notes:
Password: stdwork VA NVA % VA Secs. format shall be in "hh:mm:ss" + "a/p". i.e. 6:30:25 p
(1 sheet per person) TOTALS: 0 0 #DIV/0! Mins. & Hrs. format shall be in "hh:mm" + "a/p".
Days format shall be in base numerical format

Work Measurement
• Work measurement is studying a task and

breaking it down into elements for analysis.
• Texas A&M Engineering does two types of
Work Measurements at CCAD
• Time Standards: Full breakdown of all work
elements
• Personal, fatigue and unavoidable delays
(PF&D)
• Pace rating
• Time Observations: Concentrate on waste
elements in study
Time Standard Sheet-Summary
STD. DATA ANALYSIS/APPLICATION

OPERATION: PTO (Observation #2) DATE:
SUPERVISOR: SHOP:
MECHANIC(S): OP-CODE:
ANALYST(S): EIC/WPC:
# PROCESS SUMMARY IN OUT NORMAL TIME (min)
A Preperation 630 23.90
B Clean PTO gearshaft in varisole booth 160 7.68
C Install damper ring onto PTO gearshaft 122 7.57
D Apply label to bearing 122 19.45
E Sandblast part number onto PTO gearshaft 662 16.03
F Install bearing onto PTO gearshaft 222 12.90
G Perform backlash test on PTO gearshaft 180 24.90

Observation Work Sheet-Detail
STANDARD DATA ANALYSIS ELEMENT BREAKDOWN/LEAN ANALYSIS

OPERATION: Output Shaft CATEGORIES DATE:
SUPERVISOR: O: Operation I: Inspection CNVA SHOP:
MECHANIC(S): S: Searching P: Paperwork CVA OP-CODE:
ANALYST(S): DISTANCE T: Transport/GatheR: Rework PR:Operation NVEIC/WPC:
# Job Description IN OUT Minutes Seconds Minutes Seconds CATEGORY Obs.T. Frq. Pr Eng.
A Preperation
1 Go to inventory bins to get parts 50 0 0 0 27 T 0.45 1 0.45
2 Gathering all parts needed 0 27 1 28 PR 1.02 1 1.02
3 Go to workbench 50 1 28 1 43 T 0.25 1 0.25
4 Take parts out of bin 1 43 2 10 PR 0.45 1 0.45
5 Verify numbers match for housing 2 10 5 50 I 3.67 1 3.67
6 Verify numbers match for rotating seal and output shaft 5 50 8 24 I 2.57 1 2.57
7 Verify numbers match for bearing (1 of 2) 8 24 14 45 I 6.35 1 6.35
8 Verify numbers match for bearing (2of 2) 14 45 16 28 I 1.72 1 1.72
9 Go to QC table 20 16 28 16 35 T 0.12 1 0.12
10 Sell bearings 16 35 17 25 I 0.83 1 0.83
11 Go to workstation 20 17 25 17 33 T 0.13 1 0.13
12 Open package of common hardware 17 33 18 30 PR 0.95 1 0.95
13 Clean common hardware 18 30 21 7 CNVA 2.62 1 2.62
14 File down transfer tube 21 7 22 30 O 1.38 1 1.38
15 Inspect bearings (inspector) 22 30 23 30 I 1.00 1 1.00
16 Consult with inspector 23 30 24 20 I 0.83 1 0.83
17 Put away paperwork 24 20 25 21 PR 1.02 1 1.02
Subtotal 140 25.35
B Prepare bearings for oven

1 Open O-ring package 25 21 26 43 PR 1.37 1 1.37
2 Install O-rings onto transfer tube and jets 26 43 27 42 O 0.98 1 0.98
3 Oil up 2 jets and install in housing 27 42 29 40 O 1.97 1 1.97
4 Go to parts bin (get piston rings) 46 29 40 29 55 T 0.25 1 0.25
5 Get piston rings 29 55 30 3 T 0.13 1 0.13
6 Go to workbench 30 3 30 17 T 0.23 1 0.23
7 Install piston rings on housing 30 17 31 23 O 1.10 1 1.10
8 Measure bearings (micrometer) 31 23 32 57 I 1.57 1 1.57
9 Place hardware onto bearings (to put in oven) 32 57 33 22 O 0.42 1 0.42
10 Measure rotating seal (micrometer) 33 22 34 24 I 1.03 1 1.03

Identify Flow
Induct
Part STORAGE
GOOD
Evaluation CLEANING Component MACHINE METAL
SHOP Assembly BAD SHOP SPRAY
MACHINE WELDING MACHINE NDT Shop

SHOP SHOP HEAT
SHOP TREAT
PLATING Component
NDT Shop CLEANING
SHOP Assembly
SHOP
Finished
Typical Part Flow Product

Spaghetti Diagram
• Purpose: To help see movement of

people.
• Helps to identify waste of motion and
transportation.
• You can stand back and see the flow, see
the waste.

Spaghetti Diagram
BEFORE RIE
Total Distance 2376 ft.
(0.45 miles)
AFTER RIE
Total Distance 1256 ft.

(0.23 miles)
Savings of 1120 ft.

Value-Added Activities
1. Is the customer willing to pay for this

activity?
2. It must be done right the first time,
every time.
3. The action must somehow change the
fit, form, or function of the material
being worked.

Non-Value Added
Activities that take time, material, or

space but do not physically change the
material.
1. Defects
2. Overproduction
3. Transportation
4. Waiting
5. Excess Inventory
6. Excessive Motion
7. Non Value-Added Processing
Lean Analysis Sheet

OPERATION: PTO (Observation #1) CATEGORIES DATE:
# Job Description IN OUT Minutes Seconds Minutes Seconds CATEGORY Obs.T. Frq.
3 Wash PTO gearshaft in booth 13 57 16 22 CVA 2.42 1
3 Inspect PTO gearshaft (make sure serial # matches) 4 0 6 0 I 2.00 1

5 File down gear (double check if gear is good/bad) 7 0 7 44 I 0.73 1
7 Inspect PTO gearshaft (good/bad) 10 30 12 52 I 2.37 1
6 Inspect serial numbers match (double-checking) 17 30 18 12 I 0.70 1
5 Inspect bearing and serial #'s match 43 43 44 12 I 0.48 1
5 Sell to inspector 64 20 65 15 I 0.92 1
7 Sandblast stencil onto PTO gearshaft 32 43 33 49 O 1.10 1

2 Install damper ring onto PTO gearshaft 38 30 41 15 O 2.75 1
7 Install bearing onto PTO gearshaft using press machine 44 55 46 25 O 1.50 1
9 Torque bearing onto PTO gearshaft 47 44 50 8 O 2.40 1
1 Perform 1st run (backlash test)/ record results 50 8 53 37 O 3.48 1
2 Perform 2nd run (backlash test) / record results 53 37 54 37 O 1.00 1
3 Perform 3rd run (backlash test) / record results 54 37 56 43 O 2.10 1
7 Paperwork (fill out A&I sheets) 18 12 21 27 P 3.25 1

4 Paperwork (stamp A&I sheets) 56 43 64 20 P 7.62 1
1 Prepare to wash PTO gearshaft in varisole booth 12 52 13 30 PR 0.63 1

5 Dry PTO gearshaft 16 50 17 30 PR 0.67 1
3 Grease up PTO gearshaft 41 15 41 52 PR 0.62 1
4 Open package for bearing/put on latex gloves 41 52 43 43 PR 1.85 1
6 Put away paperwork 44 12 44 55 PR 0.72 1
1 Prepare PTO gearshaft for sandblast (apply tape ) 21 27 23 37 PR (SB) 2.17 1
3 Make stencil for part # and serial # 25 16 27 25 PR (SB) 2.15 1
4 Cut/Tape stencil onto PTO gearshaft 27 25 32 3 PR (SB) 4.63 1

Categorize/Lean Analysis
PTO Lean Analysis (Obs#1)

16.00
14.33
14.00
11.43
12.00 10.87
10.05
10.00
7.20
Tim e (m in) 8.00
6.00
4.48 3.50
4.00
2.42
2.00
0.00
CV In Op Pa Pr Pr Tr Tr
A sp er pe ep ep an an
ec ati rw er er sp sp
tio on or at at or ta or
n k ion ion tat
(S t ion io
an n
d (S
Bl an
as d
tin Bl
g) as
tin
g)
Category

Identify NVA and VA steps
(NVA & VA categories)

OPERATION: PTO (Observation #1) CATEGORIES DATE:
# Job Description IN OUT Minutes Seconds Minutes Seconds CATEGORY Obs.T. Frq.
3 Wash PTO gearshaft in booth 13 57 16 22 NVA 2.42 1
5 File down gear (double check if gear is good/bad) 7 0 7 44 NVA 0.73 1
1 Get paperwork/A&I sheets 264 0 0 2 20 NVA 2.33 1
2 Go to inventory bin (get PTO gearshaft) 122 2 20 4 0 NVA 1.67 1
7 Paperwork (fill out A&I sheets) 18 12 21 27 NVA 3.25 1
4 Paperwork (stamp A&I sheets) 56 43 64 20 NVA 7.62 1
5 Dry PTO gearshaft 16 50 17 30 NVA 0.67 1
3 Make stencil for part # and serial # 25 16 27 25 NVA 2.15 1
4 Cut/Tape stencil onto PTO gearshaft 27 25 32 3 NVA 4.63 1
6 Go to inventory bin (get another PTO gearshaft, got a bad one) 122 8 42 10 30 NVA 1.80 1
2 Go to varisole booth 80 13 30 13 57 NVA 0.45 1
4 Go to workstation 80 16 22 16 50 NVA 0.47 1
2 Go to stencil machine 316 23 37 25 16 NVA 1.65 1
5 Go to sandblast machine 26 32 3 32 15 NVA 0.20 1
8 Go to workstation 320 33 49 35 28 NVA 1.65 1
1 Go to inventory bin (get bearing) 122 37 29 38 30 NVA 1.02 1
8 Go to borrow run-on (used to torque bearing) 222 46 25 47 44 NVA 1.32 1
4 Get file brush (toolbox) 6 0 7 0 NVA 1.00 1
3 Inspect PTO gearshaft (make sure serial # matches) 4 0 6 0 NVAN 2.00 1

7 Inspect PTO gearshaft (good/bad) 10 30 12 52 NVAN 2.37 1
6 Inspect serial numbers match (double-checking) 17 30 18 12 NVAN 0.70 1
5 Inspect bearing and serial #'s match 43 43 44 12 NVAN 0.48 1
7 Sandblast stencil onto PTO gearshaft 32 43 33 49 NVAN 1.10 1
1 Prepare to wash PTO gearshaft in varisole booth 12 52 13 30 NVAN 0.63 1
5 Sell to inspector 64 20 65 15 NVAN 0.92 1
1 Prepare PTO gearshaft for sandblast (apply tape ) 21 27 23 37 NVAN 2.17 1
6 Prepare machine for sandblasting 32 15 32 43 NVAN 0.47 1
9 Take tape off PTO gearshaft 35 28 37 29 NVAN 2.02 1
3 Grease up PTO gearshaft 41 15 41 52 NVAN 0.62 1
4 Open package for bearing/put on latex gloves 41 52 43 43 NVAN 1.85 1
6 Put away paperwork 44 12 44 55 NVAN 0.72 1

Identify NVA and VA steps
PTO Observation #1
64.28
70.0
60.0
50.0
35.02
40.0
Time (min) 54.47%

30.0
16.03
20.0 13.23
24.94%
20.59%
10.0
0.0
NVA NVAN VA TOTAL TIME (MIN)
Type of Steps

Pie Chart
Cabinet for Caps Chemicals

7.7% Hardware
2.5%
1.8%
Parts Pallet
6.4%
Work Station
39.6%
PSA Table
14.5%
Special Tools
6.1%
Aircraft
21.5%

Fishbone Diagram
Pave Hawk Disassembly Fishbone Diagram
3.14 Hours 10.05 Hours 3.45 Hours
PAPERWORK
SET UP 17.7% CLEAN 6.1%
5.5%
Aircraft 40.1%
Aircraft 77.1%
44.9% Burr Tags 26.9% Part 1.3% Workstation
Hardware 8.7% FOD 15.8%

Workbook 53.6%
10.7% Workstation 0.6% Personal

1.4% Computer
Tools 5.1%
Safety Guards 9.5%
4.1% Tools
WASTE
Chemicals 2.5%
21.5% Aircraft
1.8% Searching
82.5% Confer & Assist
7.7% Cabinet Parts 6.4% Part 15.6% 56.71 Hours

2.8% PC Board 0.7% Tool
6.1% Special Tools
PSA Table 14.5%
Hardware 25.0%
0.5% PSA
1.8% Hardware
Workstation 39.6% Workbook 0.1%
INSPECTION
OTHER 4.6 % TRAVEL 27.2%
22.5%
2.62 Hours 15.40 Hours 12.78 Hours

Lean Process (Event)
• Verify Correct Process

• Observed work standard
• Flow chart or Process Map
• Spaghetti Chart
• Analyze and develop ways to eliminate
NVA steps for operator or transfer to
assistant

Verify Process Map

Value Added & Necessary Steps
4.000
VA mapping Chart 3.63
3.500
3.000
2.500
Tim e (hrs) 2.000
1.500
1.000
0.83 0.75
0.500 0.33
0.25 0.25
0.12 0.080.050.17 0.12 0.05
0.17
0.03 0.08 0.07 0.08
0.07 0.020.020.02 0.020.020.05
0.000
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Process Steps

Lean Process (Future State)
• Process At A Glance adds visual data

to create Future State for operator
• Pictures of Parts, Tools, Machines
• Kitting
• Tool lists
• Parts lists
• Hardware lists
• Standard Work Instructions
• Run the new process to verify
• Implement
Process At A Glance
•A Lean Tool that shows elements

of a process quickly.
•Task oriented.
•Helps to create Standard Work.
•Very useful for Work Cell design.

Process At A Glance
Process At A Glance breaks down

operations to steps:
•Parts
•Steps
•Tools
•Gauges
•Machines
•Instructions
•Time

Kitting
• Delivery
• Located @ point-of-use (POU)
• Issued to mechanic
• Returned empty for refill
• Contents
• Everything required for Job
• In the quantities needed

Kitting (Con’t)
• Presentation
• In the sequence used
• Cart, container, bins, etc.
• Kit design:
• Perform work right to left
• Visually signal job status
• Color code all labels
• Mistake proofing

Identify Parts Needed

Shadow Parts
Left:
Finished
Parts
Present-
ation

Identify Tool Requirements
Tools for task being laid out for

shadowing

Shadow Tools
Working Smarter not Harder

Identify New Layout
E&E and Prep

Staging for Assy
Workstation
Assy Workstation
with Special Tools
Assy Tools
E&E Tools

Document Standard Work
• Key to productivity of the whole value

stream.
• Standard Process for performing work
tasks hour by hour, day to day, week to
week.
• Process At A Glance allows simple
documenting of standard work methods.
• Can be used by operators for training
or guidance.
Kaizen Events in action

Continuous Improvement
•Know where value is created (or lost)

•Start with the end in mind
•Identify the high leverage opportunities
•Use the lean tools
•Stay on course…lean takes time
•When you think you are done…time to
start again!

Conclusion
• Work Measurement Standards historic or

new help set up Process At A Glance
events quickly.
• Process At A Glance allows processes
with a lot of variability to be
standardized.

Conclusion Con’t
• Process At A Glance allows quick

sustainable gains in productivity.
• Process At A Glance sets up future
events to level load and create assembly
lines.


Work Measurment CaseStudy

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Texas Center for Applied Technology

Work Measurement and Process at a

1 - TEES/CCAD Proprietary Information

• Preparation for Lean Event

• Value Stream Analysis

3 - TEES/CCAD Proprietary Information

• TAKT is a German word meaning Beat

4 - TEES/CCAD Proprietary Information

Typical TAKT Time Calculation:

15 Hrs (2 Shifts) = 3.63 TAKT Time

5 - TEES/CCAD Proprietary Information

Observation Time vs. TAKT Time

6 - TEES/CCAD Proprietary Information

Time observations on the shop floor

7 - TEES/CCAD Proprietary Information

• Best way to see waste.

8 - TEES/CCAD Proprietary Information

Time 2 Customer Demand units Available Time units Takt Time

9 - TEES/CCAD Proprietary Information

• Work measurement is studying a task and

STD. DATA ANALYSIS/APPLICATION

11 - TEES/CCAD Proprietary Information

STANDARD DATA ANALYSIS ELEMENT BREAKDOWN/LEAN ANALYSIS

B Prepare bearings for oven

12 - TEES/CCAD Proprietary Information

MACHINE WELDING MACHINE NDT Shop

13 - TEES/CCAD Proprietary Information

• Purpose: To help see movement of

14 - TEES/CCAD Proprietary Information

Total Distance 1256 ft.

Savings of 1120 ft.

15 - TEES/CCAD Proprietary Information

1. Is the customer willing to pay for this

16 - TEES/CCAD Proprietary Information

Activities that take time, material, or

STANDARD DATA ANALYSIS ELEMENT BREAKDOWN/LEAN ANALYSIS

3 Inspect PTO gearshaft (make sure serial # matches) 4 0 6 0 I 2.00 1

7 Sandblast stencil onto PTO gearshaft 32 43 33 49 O 1.10 1

7 Paperwork (fill out A&I sheets) 18 12 21 27 P 3.25 1

1 Prepare to wash PTO gearshaft in varisole booth 12 52 13 30 PR 0.63 1

18 - TEES/CCAD Proprietary Information

PTO Lean Analysis (Obs#1)

19 - TEES/CCAD Proprietary Information

(NVA & VA categories)

3 Inspect PTO gearshaft (make sure serial # matches) 4 0 6 0 NVAN 2.00 1

20 - TEES/CCAD Proprietary Information

Time (min) 54.47%

21 - TEES/CCAD Proprietary Information

Cabinet for Caps Chemicals

22 - TEES/CCAD Proprietary Information

Pave Hawk Disassembly Fishbone Diagram

3.14 Hours 10.05 Hours 3.45 Hours

44.9% Burr Tags 26.9% Part 1.3% Workstation

Hardware 8.7% FOD 15.8%

10.7% Workstation 0.6% Personal

7.7% Cabinet Parts 6.4% Part 15.6% 56.71 Hours

Workstation 39.6% Workbook 0.1%

2.62 Hours 15.40 Hours 12.78 Hours

23 - TEES/CCAD Proprietary Information

• Verify Correct Process

24 - TEES/CCAD Proprietary Information

25 - TEES/CCAD Proprietary Information

Tim e (hrs) 2.000

26 - TEES/CCAD Proprietary Information