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Standardized Work
Creating Continuous Flow
Presented by:
Brian D Krichbaum
Process
Coaching
Incorporated
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2008 Process Coaching Incorporated
Standardized Work
Definition
A detailed and documented system in which
production workers both develop and follow arepeatable 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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CoachingIncorporated
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Takt timeDemand RateCycle TimeProduction Time
Work Sequence
Standardized Work
Elements
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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 onthe beat.
Standardized Work
Takt Time
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Process Instruction SheetsStandardized Work Analysis Sheet (Cell Layout)
Time Observation Sheet
Operator Balance Chart
Standard Work Combination Sheet
Standardized Work
The Tools
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Standardized Work
Process Instruction Sheets
Definition
Detailed, visual instructions written from theperspective of the operator which detail the
sequence, methods, tools required and critical
to quality characteristics of an operation.
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Definition
Detailed, visual representation of the location of
everything in the workcell, includingworkstations, parts racks and storage areas,
and operators.
Used to plan the layout of cells, analyze the
amount of walking built into the process and toinstitutionalize improvements
Standardized Work
Cell Layout
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Work Instructions
Obtain Full Box of Blocks
Empty BoxPlace 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
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REMARKS
1 2 3 4 5 6 7 8 9 10 11 12
Time for each
Component
Running Time
(cumulative)Total
Time
Task Component
Observation Number Assigned ComponentTime
Time For One Cycle
Task/Process Being Observed Observer(s) Day/Time Of Observation
Step No.
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Standardized Work
Operator Balance ChartsDefini t ion
A graphical representation of the times
required by each operator in a cell tocomplete 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 SheetPart Number
Part Name
Work Sequence
Operation Time (seconds)
Man Auto W alk 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 Sec100 Sec105 Sec110 Sec115 Sec120 Sec
1
Obtain Manifold from
conveyor 15 5
2 Place in Wash Tub 10 1
3
Press Button to start wash
tub 1
4 Wash Tub Cycle 10 10
5
Obtain Manifold from
wash tub 6
6
Place manifold on work
bench 2 5
7
Obtain 4 valves from
stock area 2 5
8
Remove packaging from
valves 10
9 Place valves on manifold 8
10
Obtain screws and hand
tighten 7
11
Obtain torque wrench and
torgue to 50 ft lbs 3
12
Record torque values on
tracker 8
13 Mask off valve assembly 9
14Aside to pallet 4
15
Move to conveyor to start
next assembly 5
95 10 21
Date Prepared 10-Mar-05 Daily Demand
Step Operation
Time
231 Units
HT Injection Manifold Work Area Manifold Assembly Takt Time 117 Second
98-097-654
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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 thebottlenecks
Create another cell
When there are no other choices, operate thebottleneck in a decoupled manner (batch, notflow)
8. Ibid - page 63