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© Lean & Mean Consulting. All rights reserved. 2015 © Lean & Mean Consulting. All rights reserved. 2016
09 / 16 Standard Operations Standard Work & Process of Standardization
World-Class Standards & Best Practices of Operational Excellence
World-Class Standards & Best Practices of Operational Excellence
© Lean & Mean Consulting. All rights reserved. 2016
LEAN Management Academy - Outline Knowledge & Expertise / Editable Training Presentations / 16 Modules
3
Learning Objectives
1. Understand the importance of standardization in Lean Production System
2. Identify the key benefits and applications of standards and standard work
3. Acquire knowledge of standard work concepts, principles and tools to maximize performance and minimize waste
4
Contents
1. Introduction
2. Standardization
3. Standards
4. Standard Work
5. Implementing & Sustaining Standard Work
6. Improving Standard Work
1
Standard Work / Process of Standardization
Module. 09
6
What Is Standard Work?
Standard work is one of the most powerful but one of the most underutilized of the lean tools.
Documenting the current best methods, standardized work forms the baseline for kaizen and continuous improvement.
As the standard is improved, the new standard becomes the baseline for further improvements, and so on.
Improving standardized work is a never-ending process.
Establishing standard work relies on collecting and recording data on a few forms.
These forms are used by engineers and front-line supervisors to design the process and by operators to make improvements in their own jobs.
In this workshop, you'll become familiar with these forms and why it will be difficult to make your lean implementations “stick” without standardized work.
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What Is Standard Work?
Standard work establishes the best and most reliable methods and sequences for each process and each worker
Materials and parts
Measurements People Methods Machines (equipment)
Feed in materials
Ship to customers
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Standard Work Forms the Baseline for Continuous Improvement
Kaizen
Standardization S
D C
A
P
D C
A
Kaizen
Standardization S
D C
A
P
D C
A
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The Framework of Standardization
The practice of setting, communicating, following, and improving standards and standard work
A rule or example that provides clear explanations
A set of work procedures that establish the best and most reliable methods and sequences for each process and each worker
Standardization
Standard Work
Standards
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What is Standardization?
Standardization is the practice of setting, communicating, following, and improving standards
A standard provides the baseline upon which to measure the results of continuous improvement activities
If better results are obtained with the improved process, then the standard can be changed
The process of continually improving the standards is the path to reliable methods
Everyone must practice the standard consistently before standardization truly exists
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Ladder of Standardization
6. Improvement of management methods: Information
5. Standardization of objects: Materials
4. Building standards into equipment: Production equipment, computers, etc.
3. Standards for jigs, tools and alarm devices: Measurement
2. Standards manuals to clarify work sequences: Methods
1. Procedures explained by veteran workers: People
Step-by-step progress to
higher levels of standardization
Direction of improvement
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Documents in Manufacturing
Work Standards • Work instructions • Operation drawings • Operation instruction sheets • Process conditions sheets • Quality control sheets • Tooling layout drawings • etc.
Job Instruction • Job breakdown sheet • Cross training skills matrix • Operation instruction sheets • Etc.
Work Study/Improvement • Time study • Motion study • Work element analysis • etc.
Standardized Work • Process capacity table • Work combination chart • Standardized work chart
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Standard Work Overview
3 Requirements
3 Elements
3 Forms
Actual Standard Work in TPS
• Repetitive cyclical work • High process and part quality • Low equipment downtime
• Process capacity table • Standardized work combination chart • Standardize work chart
• Takt time • Work sequence • Standard work-in-process
Definition: A document centered around human motion that combines the elements of a job into the most effective sequence without waste to achieve the most efficient level of production.
If these forms and conditions are not met then it is not true standard work. The task is probably best suited by some form of work instruction or other standard.
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Standard Work / Process of Standardization
Module. 09
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Standard – it is a formal, written definition of the best knowledge and method of work, recognized and depicted at any given moment for satisfaction of customer requirements. Standard provides clear explanations!
What is a Standard?
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Standards
Basic features of standards:
Present the best, easiest and safest method of doing work
Constitute the best method of preserving knowledge and competence
Constitute the benchmark for work evaluation
Show the cause and effect relation
Give basis for maintaining current level and development
Are factual, simple and clear
Constitute basis for training
Are the basis for inspection and diagnosis
Are the means to prevent mistakes and minimize variability
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Regulations
Quality Standards
Specifications
Technical Standards
Types of Standards
Process Standards
Manuals
Notices
Memos
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Three Steps to Establish Standards
1. Create the standard
2. Stabilize the standard
3. Improve the standard
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Define the problem
Identify abnormal conditions
Define the standard required for normal performance
Gain team agreement on the standard
Implement the standard – communicate and train as needed
Monitor and follow up
Step 1: Create the Standard
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Standard Work / Process of Standardization
Module. 09
21
What is Standard Work?
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 aims to maximize performance while minimizing waste in each person’s operation and workload
Standard work is the fluctuating level of optimum work to be done by people and machines each day to meet customer demand
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Standard Work
Prerequisites for standard work
5S and visual controls
Quick changeover
Mistake-proofing
Total productive maintenance
Human automation
Cellular manufacturing
Pull production with kanban
Line balancing
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Six Characteristics of Standard Work
• Clear
• Correct
• Concise
• Communicated
• Current
• Complete
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Characteristics of Standard
Work
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Standard Work Must be Clear
Standard work has to be clear so that it can be followed correctly.
What is clear to one person may not be clear to another.
We need to ensure that users and auditors understand standard work the same way.
Extra jargon, verbosity, vague description or poor formatting should be avoided.
•Clear
•Correct
•Concise
•Communicated
•Current
•Complete
6
Characteristics of Standard
Work
5
Standard Work / Process of Standardization
Module. 09
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Work point of view:
Work is centered around human motion
Work is done the same way each time
Small variation in work content
Equipment point of view:
Minimal trouble with machines
Minimal fluctuation in production volume
Quality point of view:
Minimal trouble in process quality
Minimal trouble in parts and material
Ideal Conditions for Standard Work
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Three Elements of Standard Work
Standard
Work-In-Process Inventory
Takt-Time Standard
Work Sequence
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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 work-in-process inventory The minimum number of parts, including units in machines, required to keep
a cell or process moving
Three Elements of Standard Work
Standard Work / Process of Standardization
Module. 09
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Standard Work Sequence
Good
Poor
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Four Steps to Standard Work
1. Create a Process Capacity Table
2. Create a Standard Work Combination Table
3. Create a Work Methods Chart
4. Create a Standard Work Chart
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Step 1: Process Capacity Table
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Step 4: Standard Work Chart: example
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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
Step 4: Standard Work Chart
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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.
36 © Lean & Mean Consulting. All rights reserved. 2016
