1. Airbus Production System
Training Pack
Training Pack
Airbus Production System
Module: Standard Work
Element: Standard in Process Stock
Module: Standard Work
Element: Standard in Process Stock

2. Aims & Objectives
Target Audience :Operations, Manufacturing Engineering.
Purpose of Module : To gain an understanding of Standard In Process Stock (SIPS)
Aims & Objectives :
Define SIPS
To Learn how to calculate SIPS
Gain an understanding of how SIPS fits into Standardised Work
To raise awareness of how SIPS can eliminate Waste and support flow
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3. Welcome to the Standard In Process Stock Session
Definition
Best combination of man and machine to achieve output with minimum labour, space, inventory and equipment.
Objectives
To establish and clarify the guidelines for manufacturing Quality, Quantity, Manpower, Inventory, and Safety
Provides a tool for Kaizen
SIPS is part of Standard work. To understand SIPS we must first have a VERY BRIEF overview of the elements of Standard Work.
Standard work is the term used to describe the optimum combination of human work, machine work and materials.
Standard work ensures that tasks are performed following best current practice with the minimum of waste.
In Standard Work all operators should perform the same task in the same repeatable way.
Where there is no standard there can be no KAIZEN
Extra Info
Available
Prepared
Flip chart
Photo
Training
Matl.
Flip Chart
Verbal
Slide
Page 5

4. Elements of Standard Work
Flexible Work Design
Flexible Work
Design
Line Balancing
Standard Work Instruction Sheets
Takt time/ Cycle time
Standard In Process Stock
Standard
Work
Standard Work
Line Balance
Standard Operations
(SWIS.)
Takt Time
Standard
In-Process Stock
Standard work has 5 key elements.
LINE BALANCING is:- The even distribution of human work across a production area. The work is balanced to ensure that know one works in conditions of waste, overburden or unevenness.
STANDARD WORK INSTRUCTION SHEETS are:- Documents describing the best combination of man, material, and method to perform a given task. These cover a task key “knack” points, safety points, quality points and ergonomic points.
TAKT TIME is:- Time Available/Customer demand. (The pace of production)
CYCLE TIME is:- Takt time x .95 (The time taken to complete one cycle of a work process)
SIPS is:- Will cover during presentation
Extra Info
Available
Prepared
Flip chart
Photo
Training
Matl.
Flip Chart
Verbal
Slide
Page 6

5. What is Standard in Process Stock?
Standard minimum number of pieces of In Process Stock required to run each activity (Machine operation) on demand
Automatic operations require Standard In Process Stock to enable the worker to be separated from the automatic cycle
No standard in process stock is required at manual operations
The minimum number of in-process parts required to ensure the smooth operation of work without the Waste of waiting
The key thing to understand is the term IN PROCESS. This is not inventory.
SIPS enable machines to run on demand, and minimises waiting waste within work sequence. SIPS ensure that the system is PRIMED with the minimum level of stock.
S.I.P.S. considers?
Takt Time
Work sequence
Material flow
Process (Auto / manual)
Number of operators
Extra Info
Available
Prepared
Flip chart
Photo
Training
Matl.
Flip Chart
Verbal
Slide
Page 7

6. Standard in Process Stock
F.G.
R.M. B A
All manual operations:
SIPS = 0 C D E
F.G.
R.M. B A
All automatic operations:
SIPS = 5
Re-enforce the fact that manual operation do not require SIPS
(NB, The arrows denote operator movement between machines. SIPS allow the operator to keep moving. No SIPS = Waiting)
SIPS is required at any machine with an automatic cycle, manual operations are balanced to takt
Extra Info
Available
Prepared
Flip chart
Photo
Training
Matl.
Flip Chart
Verbal
Slide
Page 8

7. How do we Calculate Standard in Process Stock?
Standard in Process Stock (SIPS) can be calculated using the following equation.
SIPS = Machine Cycle Time
Takt Time
Work through an eg.
If it takes 50mins to heat treat components, and the takt time is 25 mins, SIPS will equal 2.
SIPS need to be calculated for each machine with an automatic cycle within a production cell.
Material will flow smoothly within the process with minimal stock.
The build process will include activities of transportation by different operators in the same sequence.
The work sequence is determined by the use of a work instruction sheet based on the capacity of the process.
Extra Info
Available
Prepared
Flip chart
Photo
Training
Matl.
Flip Chart
Verbal
Slide
Page 9

8. C D B E A F.G. R.M. Worked Example CT-30min CT-36 CT-60min
Machine
CT-30min D
Machine B
Machine
CT-36
CT-60min
Takt time = 6 mins
SIPS = ? E A
Machine
Manual
CT-42min
F.G.
R.M.
Work through the SIPS for machines A, B & C (Refer group to slide 9 for calculation)
SIPS = Machine Cycle Time / Takt Time
Extra Info
Available
Prepared
Flip chart
Photo
Training
Matl.
Flip Chart
Verbal
Slide
Page 10

9. C D B E A F.G. R.M. Worked Example E CT-30min
Machine
CT-30min
Therefore with SIPS and Balanced manual ops, a part will move every 6 mins D
Machine B
Machine
CT-36
CT-60min
Takt time = 6 mins
6 min E
Time E A
Machine
Manual
CT-42min
F.G.
R.M.
Work through the SIPS for machines A, B & C (Refer to slide 9 for calculation)
CLICK MOUSE- 7 SIPS for A (Appear)
CLICK MOUSE- 10 SIPS for B (Appear)
CLICK MOUSE- 5 SIPS for C (Appear)
CLICK MOUSE- 6 SIPS for D (Appear)
Ask how the group think the manual operations will be defined?
CLICK MOUSE- Line Balance (Appear)
CLICK MOUSE- Arrows and Statement (Appear)
Extra Info
Available
Prepared
Flip chart
Photo
Training
Matl.
Flip Chart
Verbal
Slide
Page 11

10. Review of Standard in Process Stock
Incorrect Standard In-Process Stock causes waste
in the sequence.
Key points to review are:-
Is the quantity set for standard in-process stock correct?
Is the quantity set for standard in-process stock strictly observed?
Is the stock in the process really necessary?
If the stock is necessary, is it at the minimum quantity?
IDEAS:-
Only carry standard in-process stock required
Locate display board at location requiring standard in-process stock,
and display the quantity standard
Incorrect SIPS causes waste in the sequence.
Once SIPS are calculated you must keep checking the process to ensure that it is working smoothly with minimum SIPS.
Make adjustments were necessary and then Standardise.
Extra Info
Available
Prepared
Flip chart
Photo
Training
Matl.
Flip Chart
Verbal
Slide
Page 12

11. Aims & Objectives
Target Audience :Operations, Manufacturing Engineering.
Purpose of Module : To gain an understanding of Standard In Process Stock (SIPS)
Aims & Objectives :
Define SIPS
To Learn how to calculate SIPS
Gain an understanding of how SIPS fits into Standardised Work
To raise awareness of how SIPS can eliminate Waste and support flow
Did we Succeed ?
Did we?
Page 13