Download - 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
N
OT
ES
( M
- W
- A
TIM
E)
US
E B
AC
K O
F T
HIS
PA
GE
TO
SK
ET
CH
WO
RK
PL
AC
E
P&
W F
OR
M 7
837
A R
EV
ISE
D 3
/97TIM
E O
BS
ER
VA
TIO
N S
HE
ET
PA
GE
OF
PA
RT
NU
MB
ER
O
PE
RA
TIO
N N
UM
BE
R
R
EV
. LE
TT
ER
S
UM
. LE
TT
ER
OP
ER
AT
OR
PA
RT
NA
ME
DE
PA
RT
ME
NT
NU
MB
ER
/ N
AM
E
PR
EP
AR
ED
BY
PC
S /
LOA
D
O
PE
RA
TIO
N D
ES
CR
IPT
ION
DA
TE
BR
AS
S T
AG
MA
CH
INE
DE
SC
RIP
TIO
N
TIM
E
T
OT
AL
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)