Standardized Work Creating Continuous Flow

Process Coaching Incorporated

Presented by: Brian D Krichbaum

Standardized Work
Definition
A detailed and documented system in which production workers both develop and follow a repeatable 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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Standardized Work
Elements

Takt time Demand Rate Cycle Time Production Time Work Sequence

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Standardized Work
Takt Time
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 on the beat.

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Standardized Work
The Tools

Process Instruction Sheets Standardized Work Analysis Sheet (Cell Layout) Time Observation Sheet Operator Balance Chart Standard Work Combination Sheet

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Standardized Work
Process Instruction Sheets
Definition
Detailed, visual instructions written from the perspective of the operator which detail the sequence, methods, tools required and critical to quality characteristics of an operation.

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Standardized Work Cell Layout

Definition
Detailed, visual representation of the location of everything in the workcell, including workstations, parts racks and storage areas, and operators. Used to plan the layout of cells, analyze the amount of walking built into the process and to institutionalize improvements

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Standardized Work
Time Observation Exercise
Job Descriptions: Production Operators Remove labels from 3 x 3 blocks Packer Pack boxes and maintain supplies Industrial Engineer Conduct time studies

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Standardized Work Time Observation Exercise

Work Instructions

Obtain Full Box of Blocks Empty Box Place 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
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Task/Process Being Observed

Observer(s) Observation Number

Day/Time Of Observation
Assigned Component Time

REMARKS

Step No.

Task Component

10

11

12

Time For One Cycle Total Time

Running Time (cumulative) Time for each Component

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Standardized Work
Operator Balance Charts
Definition

A graphical representation of the times required by each operator in a cell to complete 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 Sheet

Part Number Part Name Work Sequence
Step Operation 98-097-654 HT Injection Manifold Time Man Auto Walk 15 5 1

Date Prepared Work Area

10-Mar-05 Manifold Assembly

Daily Demand Takt Time

231 Units 117 Second

Operation Time (seconds)

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 Sec 100 Sec 105 Sec 110 Sec 115 Sec 120 Sec

Obtain Manifold from 1 conveyor

2 Place in Wash Tub 10 Press Button to start wash 3 tub 1 4 Wash Tub Cycle Obtain Manifold from 5 wash tub Place manifold on work 6 bench Obtain 4 valves from 7 stock area Remove packaging from 8 valves 9 Place valves on manifold Obtain screws and hand 10 tighten Obtain torque wrench and 11 torgue to 50 ft lbs Record torque values on 12 tracker 13 Mask off valve assembly 14 Aside to pallet Move to conveyor to start 15 next assembly
10 6 2 2 10 8 7 3 8 9 4 10

5 5

95

10

21

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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 the bottlenecks Create another cell When there are no other choices, operate the bottleneck in a decoupled manner (batch, not flow)
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8. Ibid - page 63

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