Standard Work (Sample Slides) Superfactory Manufacturing Excellence Series Lean Overview 5S & Visual Factory Cellular Manufacturing Jidoka Kaizen Poka Yoke & Mistake Proofing Quick Changeover & SMED Production Preparation Process (3P) Pull Manufacturing & Just In Time Standard Work Theory of Constraints Total Productive Maintenance Training Within Industry (TWI) Value Streams

© 2007 Superfactory™. All Rights Reserved.2Contents Introduction Background and History Components and Implementation Knowledge Check

© 2007 Superfactory™. All Rights Reserved.3Introduction Standard work is an agreed-upon set of work procedures that establish the best and most reliable methods and sequences for each process and each worker. Standard work is a tool used to best utilize people and machines while keeping the rhythm of production tied to the flow of customer orders.

© 2007 Superfactory™. All Rights Reserved.4 Components and Implementation Standards and Standardization Standard Work –Takt Time –Standard Work Sequence –Standard Work-in-Process Inventory –Four steps to Standard Work Sustaining Standard Work

© 2007 Superfactory™. All Rights Reserved.5 Types of Standards Regulations Quality Standards Specifications Technical Standards Process Standards Manuals Notices Memos

© 2007 Superfactory™. All Rights Reserved.6 Standard Work Standard work consists of three elements: –Takt time Matches the time to produce a part or finished product with the rate of sales. It is the basis for determining workforce size and work allocation –Standard work sequence The order in which a worker performs tasks for various processes –Standard in-process inventory The minimum number of parts, including units in machines, required to keep a cell or process moving Once a standard work is set, performance is measured and continuously improved

© 2007 Superfactory™. All Rights Reserved.7 Step 4: Standard Work Sheet Create a drawing of the operations in the cell and enter their sequence and description Enter the quality checkpoints Enter the safety checkpoints Enter the WIP Enter the takt time and the net cycle time Enter the amount of standard WIP Enter the breakdown numbers to indicate different operations in the cell and total number of operators

© 2007 Superfactory™. All Rights Reserved.8 Improving Standard Work Areas for improvement –Flow of materials –Shifting from specialization to multi-skilled lines and operators –Improvements in motion –Establishing rules for operations –Equipment –Separation of people and machines –Preventing defects –Eliminating walking –Shift from one-handed to two-handed tasks –Placement of parts Improvements in motion are among the most important changes

© 2007 Superfactory™. All Rights Reserved.9 Maintaining Standard Work Establish standard operations throughout the factory Make sure everyone understands the importance Trainers must be committed to the operations they teach Post visual displays to remind everyone Post graphic and text descriptions Reject the status quo Conduct group improvement activities regularly Systematically pursue improvements in standard work