std work presentation(lql)

1

STANDARD WORK

2

TRAINING OBJECTIVES

Understand basics of Standard Work Understand tools of Standard Work Provide structured, consistent approach

to eliminate waste Prepare for cell implementation, training

of associates & Value Stream Mapping

3

Definition

STANDARD WORK

Standard Work is a tool that defines the interaction of a person and the work area while performing work.

Standard Work details the motion of the operator during the work process.

4

BASICS OF STANDARD WORK

5

8 Types of Waste Over Production Waiting Motion Inventory Transportation Rework Processing

Customers

Availability? Yield? Waiting?

Inventories?Re-work?

… and people mis-utilization

6

3 DESIGN PRINCIPLES

Standard Work is a set of tools to implement these principles.

1. TAKT - Rate of production required to meet customer demand

2. FLOW - Smooth product flow with minimum in-process inventory

• Goal is 1 piece flow• Make flow visual

3. PULL - Produce what is needed, when it is needed, in the amount it is needed

7

PULLSuppliers

KCA(Kit Consolidation Area)

1

2

3

PKA(Part Kitting Area)

Suppliers

TEST

MODELB

MODEL A

MODEL A

TAKTTAKT

TAKT

FLOW

3 DESIGN PRINCIPLES

8

ELEMENTS OF WORK

Manual Operator/mechanic hands-on activity

Automatic Machine/equipment cycle

Walking Delay

Holding or waiting to perform next sequence

9

BENEFITS OF STANDARD WORK

Documents the actual process Targets areas above Takt Time Tool for continuous improvement Reduce inventory Reduce lead time Increase productivity Standardize the work process Increase capacity without increasing

resources

10

Takt Time

Work Sequence

Standard Work-In-Process

Components of Standard Work

AFSxxxxxOp10Op20Op30

11

TAKT TIMETakt time is the time in which a unit must be produced in order to match

the rate of customer demand.

• Takt Time determines rate of production• Takt Time is subject to change every month

Total daily working time

Total daily customer demandTakt Time =

11

12

AVAILABLE TIME EXAMPLE

• Weekly 6S/TPM shutdown 120 24

• Weekly QCPC meeting 60 12

• Daily cleanup 75 15

• Daily tool box meeting 25 5

Weekly Time

DailyTime

TOTAL 280 56 Min.

• Available time for 2 crews = 2 x (480 - 56) = 848 min per day

13

TAKT TIME EXAMPLE

Average Daily Schedule = 100 units

# Working Minutes = 848

= 8.48 min/unitTime available

Customer Demand=

848 Min. 100 units

Takt Time =

OrT/T = 8 minutes, 29 seconds

14

TAKT TIME, CYCLE TIME & LEAD TIME

• Takt Time = Rate of production to meet customer demand

• Cycle Time = Manual + walking + waiting time for the operator to complete one cycle of work sequence

• Lead Time = Total time required for one unit to complete entire process

= Total time for all operations + total time in all inventories

15

WORK SEQUENCEThe order in which an operator performs manual operations

including walking and waiting.

Incoming

1

2

4

3

3

1 2

1 3

2

Operator A

Operator C

Operator B

Work sequence

1

2

3

4

5

6

7

8

9

10

Process SequenceOutgoing

14

16

STANDARD WORK-IN-PROCESS

The minimum inventory required at eachworkstation to support continuous flow and

meet customer demand (Takt).Incoming

Outgoing

1

2

3

4

5

6

7

8

9

101 pc =

SWIP = 8

15

17

STANDARD WORK-IN-PROCESSOne-Piece Flow

• Each work station or machine has one piece (upstream and downstream operations must be considered…compare cycle times to Takt)

• Minimum number of pieces required for batch loads(multiply by 2 to facilitate flow - see next page)

Auto time + unload/load time

Takt Time

Batch

Min. Batch Size =

18

BATCH OPERATIONS

FurnaceAuto Cycle = 480 Min.

(Includes load/unload)

T/T = 4 Min/pc Auto time + load/unload time

Takt Time

480 Min. 4 Min/pc

(120 pieces)

Curtain

240 = Number ofSWIP for this furnace

Pull from this supply onepiece at a time for

return to one piece flow

Supply this side onepiece at a time

Batch Size =

== 120 pcs

19

TOOLS OF STANDARD WORK

20

Standard Work Tools

Time Observation

Chart

Standard

Work Sheet

Percent

Loading Chart

Standard Work Sheet Scope of From Date preparedOperations To or revised:

Quality Safety Standard Work- # of Pieces of Std. TAKT Cycle OperatorCheck Precaution in-Process Work-in-Process Time Time Number

ELEMENT NO. ELEMENT TASK 1 2 3 4 5 TASK TIME NOTES ( M - W - A TIME)

USE BACK OF THIS PAGE TO SKETCH WORKPLACE

P&W FORM 7837A REVISED 3/97

TIME OBSERVATION SHEETPAGE OF

PART NUMBER OPERATION NUMBER REV. LETTER SUM. LETTER

OPERATOR

PART NAME

DEPARTMENT NUMBER / NAME PREPARED BY

PCS / LOAD OPERATION DESCRIPTION

DATE

BRASS TAG MACHINE DESCRIPTION TIME

TOTAL

Process

Capacity Sheet2

MACHINE CAPACITY BY PROCESS PAGE _____ OF ____

NEW / REVISED DATE

PART NUMBER DEPARTMENT NUMBER / NAME

PART NAME CURRENT DAILY OUTPUT AVAILABLE TIME MAXIMUM OUTPUT PER DAY

A B C D E F G H I J KMACHINE PCS. / WALK MANUAL MANUAL AUTO TOTAL TIME / PC TIME TO # PCS. TO TIME / PC TOT / PC CALC. / REMARKS PROCESS CAPACITY

TASK # DESCRIPTION OF TASK NUMBER LOAD TIME INT EXT TIME (D + E) (F / A) CHANGE CHANGE (H / I) (G + J) (AVAIL. TIME / K)

TOTAL NOTE: REVISE TIMES WHEN SIGNIFICANT IMPROVEMENTS ARE INCORPORATED. DOCUMENT THE REASON IN THE

GRAND TOTAL "REMARKS" COLUMN.

Percent Load ChartOperators

0

10

20

30

40

50

60

70

80

90

A B C D E

Operators

Sec

on

ds

Walk

Manual External

Manual Internal

Walk

Manual External

Manual Internal

T/T2 Shift

16

4

3

32

Operation 10

Operation 20

Operation 30

Operation 40

Auto

Manual

Walk

Wait

2 shift T/T = 37 secTime, sec

50

38 38

30

STANDARD WORK COMBINATION SHEET (SWCS)

PART NUMBER OPERATION NUMBER REV. LETTER SUM. LETTER DATE TAKT TIME MANUAL AUTOMATIC

WALK VVVVVVVVV PART NAME DEPARTMENT NUMBER / NAME PREPARED BY WAIT

MAN.MACH.

STEP DESCRIPTION OF PCS / MAN NO. TASK LOAD MACH MAN AUTO

TOTAL

TIME PER PIECE USE MINUTES PER PIECE FOR STANDARD WORK DATABASE

P&W F-7837 Revised 3/97

TASK TIME: 1 LINE = MINUTES SECONDS

WALK

Standard Work

Combination Sheet5

OperationsBar Chart

21

• Old time observations• “Guesstimates”• Simulations

Time Observation

• Establish Standard Work by observation

• Multiple measures are recommended

• 2nd shortest observed time should be used

ELEMENT NO. ELEMENT TASK 1 2 3 4 5 TASK TIME NOTES ( M - W - A TIME)

USE BACK OF THIS PAGE TO SKETCH WORKPLACE

P&W FORM 7837A REVISED 3/97

TIME OBSERVATION SHEET PAGE OF

PART NUMBER OPERATION NUMBER REV. LETTER SUM. LETTER

OPERATOR

PART NAME

DEPARTMENT NUMBER / NAME PREPARED BY

PCS / LOAD OPERATION DESCRIPTION

DATE

BRASS TAG MACHINE DESCRIPTION TIME

TOTAL

Std. Work begins withtime observation

22

ELE

ME

NT

N

O.

ELE

ME

NT

TA

SK

1

2

3

4

5

T

AS

K T

IME

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( M

- W

- A

TIM

E)

US

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AC

K O

F T

HIS

PA

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TO

SK

ET

CH

WO

RK

PL

AC

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P&

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OR

M 7

837

A R

EV

ISE

D 3

/97TIM

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ER

VA

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ET

PA

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OF

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RA

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UM

BE

R

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EV

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OR

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ME

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/ N

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PR

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ED

BY

PC

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LOA

D

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RA

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CR

IPT

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DA

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BR

AS

S T

AG

MA

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DE

SC

RIP

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23

ELEMENT NO. ELEMENT TASK 1 2 3 4 5 TASK TIME

NOTES ( M - W - A TIME)

USE BACK OF THIS PAGE TO SKETCH WORKPLACE

P&W FORM 7837A REVISED 3/97

TIME OBSERVATION SHEET PAGE OF PART NUMBER

OPERATION NUMBER REV. LETTER SUM. LETTER OPERATOR

PART NAME DEPARTMENT NUMBER / NAME PREPARED BY

PCS / LOAD OPERATION DESCRIPTION DATE

BRASS TAG MACHINE DESCRIPTION TIME

TOTAL

1. Fill in all information

2. Observe operator& record tasks 3. Record elapsed time

in upper square -start at zero

4. Record task timesin lower square

5. Data accuracy increased through multiple time observation

6. Use 2nd lowesttime for task

7. Record

• Auto Times• Non repeatable Tasks• Observations • Opportunities for waste reduction

8. Compute total times

0 0 0 0 0

24

TIME OBSERVATION SHEET PAGE OF

ELEMENT NO. ELEMENT TASK 1 2 3 4 5 TASK TIME NOTES ( M - W - A TIME)

PART NUMBER OPERATION NUMBER REV. LETTER SUM. LETTER

OPERATOR

PART NAME DEPARTMENT NUMBER / NAME PREPARED BY

PCS / LOAD OPERATION DESCRIPTION DATE

BRASS TAG MACHINE DESCRIPTION TIME

770102

Blade

E. Jackson

A. Parker2643 / Small Hollow F. End

Brush

Harper Brush2/18/983:00

1

2

3

4

5

6

7

Mask Pickup / Q.V.

Insert Part. (In Mask)

Load Mask / Part

Start Auto Cycle

Unload Part

Gage

Drop Off / Q.V.

Auto Cycle = 66 sec.

0 0 0 0 02 5 5 3 52 5 5 3 5

10 12 13 12 10

7 8 10 8 85 3 5 5 3

3 4 3 4 2

3 1 2 2 313 13 15 14 1317 4 4 2 6

8 12 11 12 1030 17 19 16 19

38 29 30 28 293 4 3 4 2

3

5

3

2

4

10

3

1

2 Team Members per Observations: 1. Take 2 to 3 cycles to define the tasks. Make sure

you watch the same operator.2. Once the tasks are well defined review with the

operator.3. One person reads the watch the other observes

the tasks and calls out “time” when the task is complete. Then he/she writes in the time on the form

25

TIPS FOR TIME OBSERVATION

• Fully understand and record work sequence prior to timing

• Keep watch running continuously• Stop the watch if operator work is

interrupted• Record time for tooling changes • Stop watch time observation is faster; video

is more accurate• Time observation should be conducted with

a proficient operator

26

Production Capacity by Process

Part Process for

all parts in the cell

Operator time

(manual, walk, wait)Machine time

*Automatic (untended)

*Tooling change & dressing cycles

Separates Manual

Work From

Automatic Work

1 2 3

6 5 4

27

MACHINE CAPACITY BY PROCESS PAGE _____ OF ____

NEW / REVISED DATE

PART NUMBER DEPARTMENT NUMBER / NAME

PART NAME REQUIRED DAILY OUTPUT AVAILABLE TIME MAXIMUM OUTPUT PER DAY

A B C D E F G H I J KMACHINE PCS. / WALK MANUAL MANUAL AUTO TOTAL TIME / PC TIME TO # PCS. TO TIME / PC TOT / PC CALC. / REMARKS PROCESS CAPACITY

TASK # DESCRIPTION OF TASK NUMBER LOAD TIME INT EXT TIME (D + E) (F / A) CHANGE CHANGE (H / I) (G + J) (AVAIL. TIME / K)

TOTAL NOTE: REVISE TIMES WHEN SIGNIFICANT IMPROVEMENTS ARE INCORPORATED. DOCUMENT THE REASON IN THE

GRAND TOTAL "REMARKS" COLUMN.

28

MACHINE CAPACITY BY PROCESS PAGE _____ OF ____

NEW / REVISED DATE

PART NUMBER DEPARTMENT NUMBER / NAME

PART NAME REQUIRED DAILY OUTPUT AVAILABLE TIME MAXIMUM OUTPUT PER DAY

A B C D E F G H I J KMACHINE PCS. / WALK MANUAL MANUAL AUTO TOTAL TIME / PC TIME TO # PCS. TO TIME / PC TOT / PC CALC. / REMARKS PROCESS CAPACITY

# Process Descritption NUMBER LOAD TIME INT EXT TIME (D + E) (F / A) CHANGE CHANGE (H / I) (G + J) (AVAIL. TIME / K)

TOTAL NOTE: REVISE TIMES WHEN SIGNIFICANT IMPROVEMENTS ARE INCORPORATED. DOCUMENT THE REASON IN THE

GRAND TOTAL "REMARKS" COLUMN.

Record all information1. Record all information

2. Record operations 3. Record operation times• Manual int = machine running• Manual ext = machine stopped • Auto time

4. Record tool changes• times• frequency

5. Compute • F - Total auto + ext. manual time• G - Total time per piece• J - Time per piece for tooling change• K - Total time per pc including tooling tooling changes

6. Compute process capacity Process capacity = Available time per day / total time per pc

29

INTERNAL vs EXTERNAL

Manual Internal Operator performs manual workwhile machine is running.

Manual External Operator performs manual workwhile machine is stopped.

30

MACHINE CAPACITY BY PROCESS PAGE _____ OF ____

NEW / REVISED DATE 2/18/98

PART NUMBER DEPARTMENT NUMBER / NAME

PART NAME REQUIRED DAILY OUTPUT AVAILABLE TIME MAXIMUM OUTPUT PER DAY

840 Min.

A B C D E F G H I J KMACHINE PCS. / WALK MANUAL MANUAL AUTO TOTAL TIME / PC TIME TO # PCS. TO TIME / PC TOT / PC CALC. / REMARKS PROCESS CAPACITY

TASK # DESCRIPTION OF TASK NUMBER LOAD TIME INT EXT TIME (D + E) (F / A) CHANGE CHANGE (H / I) (G + J) (AVAIL. TIME / K)

TOTAL NOTE: REVISE TIMES WHEN SIGNIFICANT IMPROVEMENTS ARE INCORPORATED. DOCUMENT THE REASON IN THE

GRAND TOTAL "REMARKS" COLUMN.

770102 / 808302 / 808602

Blade

2643 Small Hollow - Front End

633pcs.

Brush

Mark

Chamfer

Vibratory Bowl

Polish

Wash

Plug Weld

QA Clear

1

2

3

4

5

6

7

8

1

1

1

1

1

1

40

20

2

3

2

0

1

0

0

26

30

18

0

0

0

0

0

8

6

8

56

13

46

74

13

66

19

17

0

27

0

0

90

74

25

25

56

40

46

74

103

74

25

25

56

40

46

74

103

60

30

360

180

0

30

180

10800

60

120

300

2000

0

300

300

6000

1

.25

1.2

.09

0

.1

.6

1.8

75

25.25

26.2

56.09

40

46.1

74.6

104.8

672

1996

1923

898

1260

1093

675

480

74 2248

306

480pcs.

1

1

31

TIPS FOR CAPACITY SHEET

• Do not include abnormal situations - machine goes down - set-up time (changeover) should not be included• Use caution in computing time per pc - each task time needs to be reviewed prior to normalization• Enter process steps, not individual operator tasks• Available time is same as that used in Takt time calculation

32

Operations Bar Chart

32

Operation 10

Operation 20

Operation 30

Operation 40

Auto

Manual

Walk

Wait

2 shift T/T = 37 secTime, sec

50

38 38

30

Determine balancebetween operations

32

Operation 10

Operation 20

Operation 30

Operation 40

Auto

Manual

Walk

Wait

2 shift T/T = 37 secTime, sec

50

38 38

30

Assess each operation vs Takt time

Identifies targets for Kaizen

35

2 shift T/T

Operation 20

Time

Auto

Manual

Walk

Defines operator /machine interaction

33

2 shift T/T

Operation 20

Put tasks in order they are performed

Show each manual and auto task

Time

BAR CHART SHOWS OPERATOR/MACHINE INTERACTION

Auto

Walk

Manual

34

Operation 10

Operation 20

Operation 30

Operation 40

Auto

Manual Internal

Walk

SAMPLE BAR CHART

2 shift T/T = 37 sec

Time, sec

45

38

30

Manual External

17

15

13

14

3

13

11

13

11

27

25

512

35

Bar ChartOperations

8 6 813

56

13

46

7466

19 17

90

27

0

10

20

30

40

50

60

70

80

90

100

110B

rus

h

Ma

rk

Ch

am

fer

V-B

ow

l

Po

lis

h

Wa

sh

Plu

g W

eld

QA

Cle

ar

Operations

Sec

on

ds

Manual Internal

Automatic

Manual External

T/T2 Shift74

103

56

25 25

74

4046

30 18

40 pcs

20 pcs

30

1836

36

OPERATIONS BAR CHART TIPS

• Terminology: BAR CHART, NOT % LOAD• Times should be same as on capacity sheet• Takt time must be in RED & mark # of shifts• Use color code as shown on sample• Put total time on top of bar - show individual times inside of corresponding bar• Label operation by name not number• Work in seconds• Best practice: Show manual and auto in sequence• 1st Bar Chart: Don’t normalize times• 2nd Bar Chart: Normalize for 1 pc flow• Indicate batch sizes on bar chart

37

Percent Loading Chart

Identifies targets for Kaizen

Compares cycle time to Takt time

0

10

20

30

40

50

60

A B C D

Cycle Time

T/T

OPERATORS

TI

ME

Highlights bottlenecksor available resources

1

Time n shift T/T

Operator A

Operator B

Operator C

Operator D

Operator E

ManualWalkWait

Determines balance & distribution between operators

Load ChartDate:Prepared By:Title:

Takt Time:

Cycle Time:

Load ChartDate:Prepared By:Title:

Takt Time:

Cycle Time:

175 seconds

159 SecondsSub Assembly Area 5, Widget 10005

2/14/02Mr. Oliver Operator

25

50

75

100

125

150

175

200

225

Value Add

103 Sec.

NVA 56 Sec.

TT

Operator A

Load ChartDate:Prepared By:Title:

Takt Time:

Cycle Time:

175 seconds

159 SecondsSub Assembly Area 5, Widget 10005

2/14/02Mr. Oliver Operator

25

50

75

100

125

150

175

200

225

Value Add

103 Sec.

NVA 56 Sec.

TT

Value Add

110 Sec.

NVA 25 Sec.

Value Add

135 Sec.

NVA 75 Sec.

Operator A Operator B Operator C

Load ChartDate:Prepared By:Title:

Takt Time:

Cycle Time:

175 seconds

159 SecondsSub Assembly Area 5, Widget 10005

2/14/02Mr. Oliver Operator

25

50

75

100

125

150

175

200

225

.

.

TT

Station 1 Station 2(A) Station 3

. .

Station 2(B) Station 4 Station 5

Load ChartDate:Prepared By:Title:

Takt Time:

Cycle Time:

175 seconds

159 SecondsSub Assembly Area 5, Widget 10005

2/14/02Mr. Oliver Operator

25

50

75

100

125

150

175

200

225

.

.

TT

Station 1 Station 2(A) Station 3

..

Station 2(B) Station 4 Station 5

Load Chart Examples

43

SAMPLE OPERATOR PERCENT LOAD CHART

Time n shift T/T

Operator A

Operator B

Operator C

Operator D

Operator E

Manual

Walk

Wait

# operators per shift

Total CT

T/T=

44

Percent Load ChartOperators

34

26

56

46

742

2

36

13

3

13

0

10

20

30

40

50

60

70

80

90

A B C D E

Operators

Sec

on

ds

Walk

Manual External

T/T2 Shift

Manpower = Sum of Cycle Time = 306 = 4 Takt Time 79

46

7470

41

75

45

OPERATOR PER CENT LOAD - TIPS• Takt time must be in red & # of shifts indicated• Use same color codes as bar chart• Put total time on top of bar & individual times inside bar• Show manpower calculation• Kaizen improvements to balance CT to T/T

- Understand the existing operator balance- 1st attack times that exceed T/T

- Reduce walking times & utilize waiting time- Redistribute operator work to improve balance

T/T =60”

51

45

58

43

T/T =60”

60 60 60

12

A B C D A B C D

KaizenEliminate with Kaizen

46

JT9D INDUCTION EXAMPLE

0

10

20

30

40

1

Inco

min

g In

spec

tion

2R

emov

e Q

EC

3R

emov

e As

sy. &

Exte

rnal

s

4Eng

ine

Vert.

/

Maj

or M

odul

e Spl

it

T/T

Stations

TIME

Cycle Time

50

60

5

Mod

ule

Dis

asse

mbl

y

1) Transfer work from station to station2) Productivity Improvements3) Add People

47

JT9D INDUCTION EXAMPLE

0

10

20

30

40

1

Inco

min

g In

spec

tion

2R

emov

e Q

EC

3R

emov

e As

sy. &

Exte

rnal

s 4Eng

ine

Vert.

/

Maj

or M

odul

e Spl

it

T/T

Stations

TIME

Cycle Time

50

60

5

Mod

ule

Dis

asse

mbl

y

48

STANDARD WORK COMBINATION SHEET

Visually displays manual, walking, and waiting time of mechanic

Captures the product’s cycle times; assembly, disassembly, inspection, balancing, etc.

Compares Cycle Time to Takt Time to insure proper capacity - one per mechanic

49

Standard WorkCombination sheet

Work sequence of the operator,

not the part process

Recognizes walking time of operator

One per operator

Highlights idle time, or potential shortfall

Machine cycletime displayed

50

STANDARD WORK COMBINATION SHEET (SWCS)

PART NUMBER OPERATION NUMBER REV. LETTER SUM. LETTER DATE TAKT TIME MANUAL AUTOMATIC

WALK VVVVVVVVV PART NAME DEPARTMENT NUMBER / NAME PREPARED BY WAIT

STEP DESCRIPTION OF PCS / MAN - NO. TASK LOAD MACH MAN AUTOWALK

TOTAL

TIME PER PIECE USE MINUTES PER PIECE FOR STANDARD WORK DATABASE

P&W F-7837 Revised 11/97

TASK TIME: 1 LINE = MINUTES SECONDS

WALK

CAP.

51

STANDARD WORK COMBINATION SHEET (SWCS)

PART NUMBER OPERATION NUMBER REV. LETTER SUM. LETTER DATE TAKT TIME MANUAL AUTOMATIC

WALK VVVVVVVVV PART NAME DEPARTMENT NUMBER / NAME PREPARED BY WAIT

STEP DESCRIPTION OF PCS / MAN - NO. TASK LOAD MACH MAN AUTOWALK

TOTAL

TIME PER PIECE USE MINUTES PER PIECE FOR STANDARD WORK DATABASE

P&W F-7837 Revised 11/97

TASK TIME: 1 LINE = MINUTES SECONDS

WALK

1. Fill in informationFor Std. Work

Measurement Only

2. Insert tasks from time observation

3. Fill in time and compute total time

4. Set scale based on total time

5. Takt time is RED line

6. Graph according to legend

CAP.

52

STANDARD WORK COMBINATION SHEET (SWCS)

PART NUMBER OPERATION NUMBER REV. LETTER SUM. LETTER DATE OPERATOR MANUAL AUTOMATIC

WALK VVVVVVVVV PART NAME DEPARTMENT NUMBER / NAME PREPARED BY WAIT

STEP DESCRIPTION OF PCS / MAN - NO. TASK LOAD MACH MAN AUTOWALK

TOTAL

TIME PER PIECE USE MINUTES PER PIECE FOR STANDARD WORK DATABASE

P&W F-7837 Revised 11/97

TASK TIME: 1 LINE = MINUTES SECONDS

WALK

2/18/98

79 Sec.A. Parker2643 / Small Hollow F. End

770102

1

2

3

4

5

6

7

Load Part in Mask /Q.V.

Load / Unload Part

Gage

Q.V. / Go To Mark

Load / Unload Part

Input Variable

Use Camera

1

1

1

1

1

1

1

12

8

11

3

11

6

14

66

1 X

5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95

T/T70

ATAKT TIME

Q.V. / Put Down Part8 1 5

2

3

19

5

vvvv

vvvv

vvvv

vvvv

vvvv

vvvv

vvvv

vvvv

vvvv

vvvv

vvvv

vvv

vvvvvvv

< >

Blade

CAP.

53

STANDARD WORK COMBINATION SHEET - TIPS

• Takt time must be recorded in top section and line drawn in RED

• Walk is not a separate task• Human time (CT = Manual + Walk + Wait) must be

continuous• SWCS should be for operator• If auto time less than T/T graph auto time to T/T line &

wrap around-------------------------

• SWCS can be multiple pages to show detailed operator work sequence

• Use broken scale for large imbalance of task times• Do not total the auto times• Line for CT of operator should be at approximately 45 deg

T/T0

Manual Auto

54

Standard Work Sheet

Quality Checks

Safety Precautions

Standard Workin Process

Show Machine Layout, People & Part Flow

1 2 3

45

6

( (

55

Standard Work Sheet Scope of From Date preparedOperations To or revised:

Quality Safety Standard Work- # of Pieces of Std. TAKT Cycle OperatorCheck Precaution in-Process Work-in-Process Time Time Number

56

Standard Work Sheet Scope of From Date preparedOperations To or revised:

Quality Safety Standard Work- # of Pieces of Std. TAKT Cycle OperatorCheck Precaution in-Process Work-in-Process Time Time Number

1. Fill in process start & finish

2. Diagram layout for work area/cell

3. Show operator work sequence

4. Show SWIP at each work station & record total

5. Show where inspection occurs

6. Mark location for safety precaution

7. Insert T/T

8. Insert operator CT

9. Insert operator #/ Total operators

57

Standard Work Sheet Scope of From Date preparedOperations To or revised:

Quality Safety Standard Work- # of Pieces of Std. TAKT Cycle OperatorCheck Precaution in-Process Work-in-Process Time Time Number

QAClear

PlugWeld Wash Polish Deburr

VibroBowl

BurnOut

EDM Brush ChamferIncoming

BrushQA Clear

79 Sec.123

2/18/98

Mark

5306

X 2 X 2

58

STANDARD WORK SHEET - TIPS

• Work sequence must be numbered• Show return trip with dashed line (no value

added)• Indicates part leaving line

Heat Treat

• Does not have to be to scale, but show distances

• Operator represented by (

59

MANPOWER REQUIREMENTS

• Manpower to work to maximum capacity

Total human work (cycle) time based on 1 pc

Total time per pc for slowest operationOperators Needed per shift =

Barriers • Contractual obligations• Operator skills• Layout• Operator willingness

• Manpower required to meet customer demand

Operators Needed per shift

Takt Time=

Total human work (cycle) time based on 1 pc

60

Time obs.

ProcessCapacity

% Load

Std work sheet

SWCS

OperationBar Chart

MakeImprovements

IMPLEMENTATION OF STD WORK

VA

LU

E S

TR

EA

M M

AP

PI N

G

61

SUMMARY

• Basic principles of JIT manufacturing• Takt • Flow • Pull

• Standard Work Components• Takt Time • Work Sequence• Standard Work-in-Process

• Standard Work Tools• Time Observation Form• Capacity by Process • Bar Chart• Per Cent Loading• Standard Work Combination Sheet• Standard Work Sheet

62

ADDITIONAL TOOLS

63

P-Q Analysis BU 263 Cell#3

0

1250

2500

3750

5000

6250

7500

8750

10000

11250

12500

7947

01

8400

01

8086

02

8559

01

7701

02

8083

02

8560

01

8083

12

8561

01

8392

01

8157

21

8158

21

8157

41

8159

41

7951

32

8158

31

8540

01

Qu

anit

y

0.00%

20.00%

40.00%

60.00%

80.00%

100.00%

120.00%

To

tal %

64

PROCESS MATRIX

Part #

Machine

Part Type

Process

794701

840001

808602

856001

770102

BT 500526

Brush Mark ChamferBurn Out

VibraBowl Polish Wash

PlugWeld

Blade

Blade

Blade

Blade

Blade

2 3 4 5 6 7 8

1

1

2 3 4

1 23 4 5

1

1

2

2

3

3

4

4 5

BT 007936 BT 237909 BT 505300BT 421789 BT 511893 BT 356432 BT 111233

** All numbers used are for illustration purposes only.

65

Part Number______________

Process at a Glance

Process Sketch

Work Methods

Measuring Gages

Jig or Fixture

Cutting Tools

Machine

Ti

me

Manual

Machine

Setup

Process Name

Step # Takt Time______________

Comments:

66

Spaghetti Chart Measures the travel distance of the products and the travel

distance of the operator in order to highlight unnecessary travel waste. PW4000 2nd STAGE HPT VANE

PROCESS CENTERS FLOW

7,992 FT8 WEEK LEADTIME

BEFORE

NORTH HAVEN FACILITY - 1st Floor

1,117 FT3 WEEK LEADTIME

AFTER

67

N2-FCU Ass’y / I2-Line (before)

A1 A2 A3 A4 A5 A6

A7A8

A9A12 A10A11A15 A14 A13

B3

B2

B1

C1

D1 D2

WIP

INSPECTION R/M

P.P BANDING M/C

CREW SIZE = 21

STANDARD WORK SUMMARY(C1)

68

69

70

71

72

Collect Current Demand Data by Model

Determine Available Time to Produce Demand

Establish TAKT Time

Collect Current Work Content Times

Complete Standard Work Combination Sheet and Create Load Chart

Eliminate Waste by Separating Value-added and Non-value-added Activities

Redistribute Work Content to Meet TAKT Time and Create New Load Chart

Establish Standard Work-in-process

Verify New Work Content Times and Redistribute Again as Necessary

Establish Method Sheets for Each Operation to Document Standard Method

Steps to Implement Standard Work

73

74

75

N-2 FCU Ass’y / I 2 - Line (after)

A1

A2 A3

A4

A5 A6

A7A8

A9A12

A10A11

A15 A14 A13

B3

B2

B1

D1

C1

WIP

INSPECTION R/M

P.P BANDING M/C

CREW SIZE = 11

STANDARD WORK SUMMARY(C2)