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Standardized Work Creating Continuous Flow Presented by: Brian D Krichbaum Process Coaching Incorporated
Process Coaching Incorporated Page 2 of 59 © 2008 Process Coaching Incorporated 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.
Process Coaching Incorporated Page 3 of 59 © 2008 Process Coaching Incorporated Takt time – Demand Rate Cycle Time – Production Time Work Sequence Standardized Work Elements
Process Coaching Incorporated Page 4 of 59 © 2008 Process Coaching Incorporated 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. Standardized Work Takt Time
Process Coaching Incorporated Page 5 of 59 © 2008 Process Coaching Incorporated Process Instruction Sheets Standardized Work Analysis Sheet (Cell Layout) Time Observation Sheet Operator Balance Chart Standard Work Combination Sheet Standardized Work The Tools
Process Coaching Incorporated Page 6 of 59 © 2008 Process Coaching Incorporated 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.
Process Coaching Incorporated Page 7 of 59 © 2008 Process Coaching Incorporated 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 Standardized Work Cell Layout
Process Coaching Incorporated Page 8 of 59 © 2008 Process Coaching Incorporated 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
Process Coaching Incorporated Page 9 of 59 © 2008 Process Coaching Incorporated 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 Standardized Work Time Observation Exercise
Process Coaching Incorporated Page 10 of 59 © 2008 Process Coaching Incorporated
Process Coaching Incorporated Page 11 of 59 © 2008 Process Coaching Incorporated 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.
Process Coaching Incorporated Page 12 of 59 © 2008 Process Coaching Incorporated
Process Coaching Incorporated Page 13 of 59 © 2008 Process Coaching Incorporated 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) 8. Ibid - page 63
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7-1Design of Work Systems Job design involves specifying the content and methods of job. IN general the goal of the job design is to create a work system.
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