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Standard Work

Standard Work. Superfactory Manufacturing Excellence Series Lean Overview 5S & Visual Factory Cellular Manufacturing Jidoka Kaizen Poka Yoke & Mistake Proofing Quick Changeover & SMED Production Preparation Process (3P) Pull Manufacturing & Just In Time Standard Work

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Standard Work

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  1. Standard Work Superfactory Manufacturing Excellence Series Lean Overview 5S & Visual Factory Cellular Manufacturing Jidoka Kaizen Poka Yoke & Mistake Proofing Quick Changeover & SMED Production Preparation Process (3P) Pull Manufacturing & Just In Time Standard Work Theory of Constraints Total Productive Maintenance Training Within Industry (TWI) Value Streams

  2. Contents • Introduction • Background and History • Components and Implementation • Knowledge Check © 2007 Superfactory™. All Rights Reserved.

  3. Introduction • 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 is a tool used to best utilize people and machines while keeping the rhythm of production tied to the flow of customer orders. © 2007 Superfactory™. All Rights Reserved.

  4. Components and Implementation • Standards and Standardization • Standard Work • Takt Time • Standard Work Sequence • Standard Work-in-Process Inventory • Four steps to Standard Work • Sustaining Standard Work © 2007 Superfactory™. All Rights Reserved.

  5. Types of Standards • Regulations • Quality Standards • Specifications • Technical Standards • Process Standards • Manuals • Notices • Memos © 2007 Superfactory™. All Rights Reserved.

  6. Standard Work • 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 in-process inventory • The minimum number of parts, including units in machines, required to keep a cell or process moving • Once a standard work is set, performance is measured and continuously improved © 2007 Superfactory™. All Rights Reserved.

  7. Step 4: Standard Work Sheet • 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 © 2007 Superfactory™. All Rights Reserved.

  8. 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 © 2007 Superfactory™. All Rights Reserved.

  9. Maintaining Standard Work • Establish standard operations throughout the factory • Make sure everyone understands the importance • Trainers must be committed to the operations they teach • Post visual displays to remind everyone • Post graphic and text descriptions • Reject the status quo • Conduct group improvement activities regularly • Systematically pursue improvements in standard work © 2007 Superfactory™. All Rights Reserved.

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