Standardized Work

Standardized Work 1
 Objective

To support the operator with an efficient and

repetitive method that achieves the safety,
ergonomics, and quality standards required to
compete in today’s environment.

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 Expectations
 Better understanding of standardized work elements
and how they affect overall efficiency and quality:
− Cycle time

− Process sequence

− Foot print/walk path

− Work in Process (WIP)

 How to utilize this information to identify waste,

propose opportunities for improvement, and optimize
operator work stations

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 Definition of Standardized Work
The documented, current best method to safely and
efficiently perform work that meets the necessary
level of quality and provides the standard for
continuous improvement.

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 What Does It Look Like?
• Operation methods are thoroughly
documented in a way that enables operators
to complete the task, and they are posted at
the work station.
• Operators follow the same steps each time
they do the work.
• By doing work consistently, operators use the
proper tools and machines.

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 What Does It Look Like? (cont’d)
• Material is stored in the same place everyday.
• Information is presented in the same format
throughout the plant.
• Methods and results are improved continuously,
and the documentation is updated to reflect the
new standard process.

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 Purpose of Standardized Work
• Capture and use best methods
• Build quality, safety, Work-In-Process (WIP)
limits, and productivity considerations into steps
• Change easily (continuous improvement)
• Identify areas of waste, which are opportunities
for improvement

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 What Are The Benefits?
• Clear accessible documentation of the
best method
• Documented work is done consistently
• Consistent methods get consistent
quality results
• Consistent quality increases job security,
customer satisfaction, and competitiveness.
• Enables new team members to learn more
efficiently.
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 What Are The Benefits? (cont’d)
• Learning from others’ experiences (shared
learning)
• Problems are easier to spot quickly
• Reduces costs associated with process variation
• Provides baseline from which to improve
• Your expertise is reflected in the standard

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 Is 99% Quality Good Enough?

• Two unsafe landings at O’Hare Airport each day

• 20,000 incorrect drug prescriptions filled each year
• 22,000 checks deducted from the wrong accounts each
hour
• 55 malfunctioning automatic teller machines will be
installed in the next 12 months
• 107 incorrect medical procedures performed each day
• No telephone, electricity, or television for 15 minutes a
day
• 12 babies given to the wrong parents each day

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 The 4 Elements

• Takt Time/Line Cycle Time

• Work Sequence/Standard Work Layout

• Standard Work-In-Process (WIP)

• Standard Work Instruction (SWI)

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 Takt Time vs. Line Cycle Time
• Definitions
– Takt Time is how often (in seconds) a unit must be
produced to meet customer demand
– Line Cycle Time is the amount of time that the
vehicle/unit is physically in the work station

• Formulas
Net Operating Time per Period
Takt Time = ------------------------------------------
(seconds) Customer Requirements per Period

Line Cycle Time = Takt Time – Overspeed

(seconds)

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 Takt Time: Example

Net Operating Time (One shift operation)

Shift 480 min. (8 hrs. X 60 min. per hr.)
Morning Break - 10 min.
Afternoon Break - 10 min.
Net Operating Time 460 min. (27,600 sec.)

Customer Requirements per Day = 480 per shift

A unit must be produced

27,600 seconds 57.5 sec. every 57.5 seconds to
480 units = meet customer demand.

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 Potential Improvements Summary
Improvement
Items Current Proposed
Qty. %

1. Manpower

2. Inventories
(F.G. &
W.I.P.)

3. Workspace
(Sq.Ft.)

4. Lead Time

5. Part Travel
Distance

6. Other

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 Self-Test—Standardized Work

1. Standardized work allows an organization to do which of the following?

a. Increase number of vehicle produced.
b. Utilize the latest, most efficient methods for the specific operation.
c. Decrease plant inventory.
d. Increase EHPV.

2. Standardized work has which of the following characteristics?

a. Operators follow the same steps each time they do the work.
b. Material is stored in the same place everyday.
c. Information is presented in the same format throughout the plant.
d. Once standardized work is established, it should remain in place
and unchanged for at least 3 years.

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 Self-Test—Standardized Work (cont’d)

3. The benefits associated with implementing standardized work include:

a. More consistent quality results.
b. Easier learning of new jobs or tasks.
c. Problems are easier to detect.
d. Operators learn from one another’s experiences.
e. All of the above.

4. Developing a Standard Work Instruction (SWI) with operator input will

most likely result in the process and steps being followed by the
operator.
True False
5. Standardized work does rely heavily on the determination of Value
Added and Non-Value Added activities.
True False
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 Types of Questions on the Floor
1. Is the standardized work posted and updated?

2. Is it easily understood? Ask the operator to

explain the standard operation.

3. Is the standardized work being followed?

4. Is the operator able to complete the operation in

adequate time?

5. Does the operator have the correct amount of

work?
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 Summary
• Cyclical work providing a safer working
environment
• Promotes efficient operations at lower costs,
through a controllable and stable process while
ensuring good quality
• Visual control to aid in continuous improvement
activities, training, and re-balancing

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 Key Points
• See station through the eyes of the operator
• Understand operator work sequence
• Identify Value Added (VA) and Non-Value Added
(NVA) and improve
• Improve efficiency through improved layout and
work flow; work smarter with more value added
work content

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 Training Room Activity Timing
• Review the current state 10 min.
• Develop proposed state 30 min.
– Standardized Work Analysis Worksheet
– Potential Improvement Summary Worksheet

• Presentations and discussion 20 min.

Total time: 60 min.

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 Standardized Work Analysis

Current Station # ____________________ Cycle Time _______ Efficiency ______

Station Desc ____________________ Observed Time _______ Utilization ______
Station Location __________________ Available Time _______ OFI ______
Proposed Value Added Content ______

Opportunity Work Station Lay-out

USE DIRECTIONAL ARROW TO DENOTE CARRIER PATH.

Walk/
No. Work Elements Work
Wait
Machine

Sub-totals:

Total Observed Cycle:

Percent of Observed Cycle:

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 Standardized Work Analysis

Station # HVAC A/1

____________________ Cycle Time 48 sec
_______ Efficiency 44%
______
Current
Schedule HVAC
Station Desc ____________________ 21 sec
Observed Time _______ Utilization 31%
______
G & H 26
Station Location __________________ 27 sec
Available Time _______ OFI 33 sec
______
Proposed 15 sec
Value Added Content ______

Opportunity Work Station Lay-out

USE DIRECTIONAL ARROW TO DENOTE CARRIER PATH.

Walk/
No. Work Elements Work
Wait
Machine

1 Remove label from strip 2 3 Main Line

2 Apply label to part 1 Platform
3 Get part 1,2,3, or 4 1 3
4 Peel/dispose paper 1
5 Apply gasket to part 10
FOCUS AREAS
BELT 1
1 Operators Waiting
Conveyor 2
2 Conveyor
3 Over / Under
4 Storage / Inventory
5 Space Utilization

4
3 3

Part Part Part

A 1
4 Printer 2 1,2,3,or4
15 6 0
Sub-totals:
Part Part Part
Total Observed Cycle: 21 3 1 1,2,3,or4
Percent of Observed Cycle: 71 29

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 Standardized Work Analysis

Station # HVAC A/1

____________________ Cycle Time 48 sec
_______ Efficiency 77%
______
Current
HVAC schedule
Station Desc ____________________& subassy 37 sec
Observed Time _______ Utilization 65%
______
G & H 26
Station Location __________________ 11 sec
Available Time _______ OFI 17 sec
______
Proposed 31 sec
Value Added Content ______

Opportunity Work Station Lay-out

USE DIRECTIONAL ARROW TO DENOTE CARRIER PATH.

Walk/
No. Work Elements Work
Wait
Machine

1 Remove label from strip 2 3

2 Apply label to HVAC part 1
3 Get HVAC part 1 3 Platform

4 Peel/dispose paper 1
5 Apply gasket to HVAC 10
Hoses
6 Place HVAC in fixture 1 Gaskets

7 Get clamp 1 Printer Clamps

46
8 Place clamp in tool 1 A HVAC
HVAC Modules
Modules 46
9 Get hose 1 HVAC 46
Modules
10 Dip hose/slide thru clamp 2
11 Attach hose to HVAC 1
12 Clamp hose 1
13 Repeat 7-12 for 2nd hose 7
14 Remove HVAC fr fixture 1

Sub-totals:
31 6 0
Total Observed Cycle: 37
Percent of Observed Cycle: 84 16

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