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IENG 451

IENG 451. Standardized Work. Standardized Work . Benefits of Standardization Process stability – stability means repeatability Clear stop and start points for each process Organizational learning Employee involvement and poka -yoke (error proofing) Kaizen – continuous improvement

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IENG 451

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  1. IENG 451 Standardized Work

  2. Standardized Work • Benefits of Standardization • Process stability – stability means repeatability • Clear stop and start points for each process • Organizational learning • Employee involvement and poka-yoke (error proofing) • Kaizen – continuous improvement • Training

  3. Sources of Instability • Quality problems with incoming parts • Problems with machines, jigs • Parts shortages • Waiting for a part • Safety problems

  4. Elements of Standard Work • Takt time • Work sequence • In-process stock • Goal is to synchronous Takt time and cycle time

  5. Elements of Standard Work • Work sequence • Pick up part • Walk to machine • Place part on machine • Machine process part • Take part to next machine

  6. Elements of Standard Work • In-process stock • Minimum number of unfinished parts required for operator to complete the process without standing in front of a machine • Quality checks require additional in-process • Temperatures must fall for next operation (more) • Machinery cycles automatically (more)

  7. Production Capacity Chart Basic Operation Time Tool Changes Time To comp. Inter changes Mach Time Man Time Time to change Name No M/C Capacity 1 Machine face 3 MIL 1764 25 28 100 60 965

  8. Standard Work Table

  9. Standard Work Chart

  10. Job Element Sheets

  11. Line balancing time 1 2 3 4 5 6 Station time 1 2 3 4 5 6 Station

  12. Overall vs Individual Efficiency • Goldratt – Drum, Buffer, Rope • Identify bottlenecks • Exploit bottlenecks • Elevate bottlenecks • Baseball cap factory

  13. Standardized Work and Kaizen • Guidelines for economy of motion (IE 311, 321) • Guidelines for layout • Guidelines for tools/jigs

  14. Standardized Work and Kaizen • Guidelines for economy of motion (IE 311, 321) • Hand movements symmetrical and current • Light work • Done in a strong circle • Keep hands free • Guidelines for layout • Guidelines for tools/jigs

  15. Standardized Work and Kaizen • Guidelines for economy of motion (IE 311, 321) • Guidelines for layout (IE 471, 475) • Use gravity • Horizontal vs vertical movement • Place tools and materials for easy access • U-cells • Guidelines for tools/jigs

  16. Standardized Work and Kaizen • Guidelines for economy of motion (IE 311, 321) • Guidelines for layout (IE 471, 475) • Guidelines for tools/jigs (IE 475) • Eliminate manual holding • Use ergonomic tools • Combine tools where possible

  17. Common Layouts • Job Shop • Cells • Assembly Line • Strategies • Chase • Level • Mixed

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