Production System Effiency
STANDARDIZED WORK
TRAINING
Definition – Standardized Work A timed description of the best possible succession of basic manual tasks for an operator.
It includes:
- transformation and control operations
- but also movements
- other necessary steps included in the cycle time.
Objective
Achievement of safety, quality, productivity and delivery performance objectives through:
• reduce dangerous movements
• apply controls and ability to repeat
• correct use of machines
• identification and elimination of the 7 wastes
• training and evaluation of the operators
Key Factors•Allows the repeatability of the sequence of basic tasks during each cycle with low variability of the process.
•Work content may differ according to product options
• Separate the man and machine
• Reduce frequencial operations (reduce variability)
• Quick and efficient treatment process of improvement ideas through the operator
Cycle Time and Takt Time
Takt time is a rate that represents, in seconds, the number of parts the customer expect us to deliver
Cycle time is a rate, in seconds, at which the product must be produced in order to offset “waste” in the system and achieve the Takt Time needed to satisfy the customer
Work ContentSum of the basic tasks carried out at each workstation to obtain a complete and good product (amount of work for a part)
It is measured by timing the cycle of each operator using a cycle time measurement form. The measurement must be based on 20 consecutive cycle times (everything included).
Time necessary for self-inspection has to be included.
For each operator, we will show the minimum time, wait time excluded, as well as the maximun and mean time.
FORMS
The standardized work goal is based on 3 forms:
• Standardized Work Chart ( FAU-F-PS-5006)
• Work Combination Table (FAU-F-PS-5007)
• Standard Operation Sheet (FAU-F-PS-0241)
Standardized Work Chart
- describes the succession of basic tasks and the position of the operator for each of them.
- helps to visualize easily the operator movements and to identify useless movements
- determines the number of parts between each workstation.
Standardized Work ChartOperation from: Date:
to:
Takt Time Expected nb parts waiting
61 s
Cycle time
51 s
Expected number of parts waiting
3
FAU-F-PS-5006 /1
Product: panel Process: welding, assembly
Standardized work chart
Machine 4 (Welding)
Station 5 (Inspection)
FP cart12
3
4
5
6
710
8
9
Sketch operator's workstations. Break his/her work down into elementary tasks corresponding to those in the standard work combinaison table.
Number the operator's position for each job
Add symbols
Part awaiting operator (e.g. At end of cycle)
Special hasard or safety action
Qualityinspection
Safety
Movement
w ith part
w ithout part
Productionname:
date:
Methodsname:
date:
Qualityname:
date:
Work Combination Chart
- gathers all the basic identified tasks on the Standardized Work Chart and details each specific time.
- helps differentiate times walking and waiting from working on the workstation.
- allows to evaluate the difference between cycle time and takt time and to verify that operators do not wait for the machine.
Work Combination Chart
/ / / / / /
SYMBOLS: - MANUAL: AUTO: WALK: IDLE:15
PRODUCT REFERENCE NUMBER:
WORKSTATION ANALYZED BY:
TAKT TIME: Quality
Volume:
DATE:
Production Methods
STANDARDIZED WORK COMBINATION TABLE
TIME OPERATION TIME
WALKAUTOMANUOPERATION NAME
N° 45 6015
2
3
15TOTAL
35
30
3
2
4Functional inspection
3
310Position part for inspection
3 Weld
Welding inspection
2
3
Pick waiting part
2Position part
1
5 15
Place part in cart
9 Pick welded part
2
7 Pick inspected part 2
Surface inspection
5
6
8
3
50
3
34
25
2
555 10 403020
CT = 51s
TT = 61s
Record time spent on:- manual operations - automatic operations- walking (1m = 1s)
Break work down into elementary tasks, numbered as in the standard work chart
Represent the times graphically, differentiating among:- manual time ( ______ )- automatic time (-----)- walking (~~~~)- idle time (====)
FAU-F-PS-5007 /1
Standard Operation Sheet
- details all the instructions to realize an operation at a workstation describing it by the safest, easiest and most efficient way.
- contrary to the standardized work chart and work combination table relative to an operator, this document is linked to a process or a basic operation from the process.
Standard Operation Sheet
STANDARD OPERATION FAU-F-PS-241 / ENversion 02
Part Number xxx Part Name Bolster
Name:
= SAFETY = QUALITY = TIP
Issued Signature/Date Checked Signature/Date
Name: Name:P lace rejects in reject container. Record on P rocess Monitor
Sheet. If 3 or more rejects found with same fault call Gap Leader.Function: Function: Function: Name:
Signature/Date SKILLED
OPERATOR
Non Conforming Product:Approved Signature/Date
5 Place one white & green clip into cavities 3&4
- Take one white & green LH clip from the dispenser.- Place the green clip into the center clip position and the white into the bottom location on cavity 4.- Take one white & green RH clip from the dispencer.- Place the green clip into the center cl
4Remove the spiked frame from the underneath bench
Remove the spiked frame from underneath the bench place it into the guides on the upper mould tool (fig 1)
Ensure that the handle is pointing towards you is fully located against the censor
3 Fold waste and place onto to stand.
Fold the waste from the frame and place it onto the granulator cooling stand, using it to push the existingwaste into the granulator (fig 2).
2Remove the spiking frame from the upper tool
Remove the waste then place the frame onto the bench
Ensure frame handle is pointing away from you and spikes are pointing upwards.
1 Remove parts from tool Remove cavities 3 & 4 from the mould tool.Place parts onto left side of bench (Fig1)
No. Operation 30 Sec Sketches / Photo's / etc.
Line : EQ Bolster Work-station: Woodstock
Plant: Washington
4
Granulator
1
Safety issue: to be used if a real risk exists for employees !
Important remarks can be written in bold or underlined
Operator who participated in setting up the Standard Operation
Non-ComformanciesReaction rules have to be adapted to the workstation
Tip : put the stress on special comments
Whole Time needed according to the Standardized Combination Table
big fontenables operator to read from worstation
"Alt+Enter"to go on the next line in the same cell
Self-Quality check
Time:
Standard Operation Sheet
Fig 1.
Fig 2.
Fig 3.
STANDARD OPERATION FAU-F-PS-241 / ENversion 02
Function:
5 Place one white & green clip into cavities 3&4
- Take one white & green LH clip from the dispenser.- Place the green clip into the center clip position and the white into the bottom location on cavity 4.- Take one white & green RH clip from the dispencer.- Place the green clip into the center cl
Signature/Date
2Remove the spiking frame from the upper tool
4Remove the spiked frame from the underneath bench
3 Fold waste and place onto to stand.
Remove the waste then place the frame onto the bench
Ensure frame handle is pointing away from you and spikes are pointing upwards.
Fold the waste from the frame and place it onto the granulator cooling stand, using it to push the existingwaste into the granulator (fig 2).
Remove cavities 3 & 4 from the mould tool.Place parts onto left side of bench (Fig1)
Sketches / Photo's / etc. = SAFETY = QUALITY = TIP
Signature/Date Signature/Date
xxxx
4
1/1
Document No.:
Rev ision Level:
Woodstock
Washington
Work-station:
Plant:
P lace rejects in reject container. Record on P rocess Monitor Sheet. If 3 or more rejects found with same fault call Gap Leader.
Name: Name:
Non Conforming Product:
Function:
Signature/DateIssued Checked
Name:Function:
1
30 Sec
Remove parts from tool
Operation No.
Remove the spiked frame from underneath the bench place it into the guides on the upper mould tool (fig 1)
Ensure that the handle is pointing towards you is fully located against the censor
SKILLED
OPERATOR
Approved
Name:
xxx Page No:
Part Number
Part Name Line :Bolster EQ Bolster
Cavities
Spiking
Cavities 234 1
Granulator
Cooling stand
White
GreenWhite
1 2
3
4
5
Time: