Table of contents
- Standard Work
- What is Standardization?
- Standard Work Steps
- The three elements of Standard Work
- Benefits of Standard Work
- 6 steps to achieve Standard Work
- Three basic forms used in Standard Work
- Related Articles
Standard work can include many elements such as the operator procedures, key steps, work locations, machine or technology used, production sequence, safety concerns, quality checks, and work locations. It also indicates the inventoryMuda (無駄, on'yomi reading) is a ... Learn More... location and quantity within the system. The standard work visual, also known as a standard layout, shows the operator’s movement rangeIn statistics, the range of a set of data is the differenc... Learn More... and product flow path. It includes information about the operation cycle timeThe cycle time is the time it takes to produce an item or pr... Learn More... as well as the TAKTTAKT Time Definition Takt time, or simply Takt, is a manufac... Learn More... times for each product.
The standard work should be documented and presented in its entirety. It should also demonstrate the desired properties of any work performed. It is essential to document the standard work to keep the system repeatable and predictable. Non-documented systems are less likely than those that follow best practices.
What is Standardization?
Standardization is the processThere are many ways to organize your lean six sigma processe... of creating rules that outline how employees should perform a set of tasks. It also creates a penalty for not complying. This practice reduces the risk of critical details being missed and eliminates ambiguity, wasteMuda (無駄, on'yomi reading) is a ... Learn More..., as well as safety hazards.
Standard Work Steps
Define or identify a standard
Identify areas in which best practices are not available or are inadequate.
Converge on the standard
Once you have defined the standard, share it with the team. It is important that everyone knows what the standard is and how it can improve processes. Everyone must also commit to the standard.
Verify that the standard is reasonable and that it is easy to follow
To determine if the standard is reasonable, fair, and feasible to follow, you should evaluate it. You may have to amend the standard to clarify or streamline certain tasks.
The three elements of Standard Work
Standard Work consists of three elements that define the requirements to meet customer demand and create stability.
1- Work Sequence
The steps that operators must complete within TAKT timeTAKT Time Definition Takt time, or simply Takt, is a manufac... Learn More... and in the correct order.
2- Standard inventory or in-process stock
Minimum number of parts and materials required to operate the process.
3- TAKT or PITCH Time
The rate at which services, products, or parts must be produced to meet customer demand.
This simple equation can be used to calculate takt time:
TAKT time = Net Available Time per day / Customer Demand per day
Benefits of Standard Work
Help your people
Sometimes operators believe that because their work is so varied, it cannot be standardized or that they will have to work in monotony if they are not standardized. It is the reverse: standardizing work increases efficiency and allows for more creative work.
Operators can also use standardized work to organize their work. This reduces stress and relieves operators from the pressure of incorrectly performing tasks.
Standardized work also makes it easier to train new employees, as it clearly documents how to do each process. This ensures that all new employees have the same information as other operators.
Improves Continuous Improvement
Kaizen is another LEANLEAN Definition LEAN is a production method aimed primarily ... Learn More... principle. It’s the idea of continuous improvementContinuous improvement (or Kaizen) is a way to identify oppo... Learn More.... Kaizen is based on standard work. It is possible to objectively evaluate changes only when procedures are documented and standardized. As standards improve, is the new standard for Kaizen. This will allow for further improvements. It’s a never-ending process to improve standard work.
It is more difficult for operators to spot 8 Lean Manufacturing wastesMuda (無駄, on'yomi reading) is a ... Learn More... when they perform different tasks. It is easier to identify opportunities for improvement when processes are consistent.
Variability is reduced
Standard work decreases variation in output by standardizing the most efficient ways to do processes. It is possible to predict the outcome of work: costs, quality, inventory requirements, and delivery times.
6 steps to achieve Standard Work
Step 1: Collect data about your current operations
Establishing your TAKT or PITCH timeTAKT Time Definition Takt time, or simply Takt, is a manufac... Learn More... and work order is the first step. Consistently, metrics such as the cycle time and step times per operator are recorded. Companies have real-time visibility of their operations. This allows them to see exactly what tasks are being completed.
Step 2: Take note of variations and problems
There are often multiple ways to accomplish a task. However, only one uses information, resources-materials, and machines in the most efficient manner possible.
Look at the data that you have collected and note any variations. Do you see workers who do the same job but produce different results? Do some workers take longer than Takt? Can some tasks be combined? Are their safety or quality concerns?
Step 3: The most efficient way to manage your operations
You can use LEAN tools to optimize the flow of your work and improve your processes. You could use value stream mappingWhat is a Value Stream Map? Six Sigma's Value Stream Map is ... Learn More... or poka-yoke to error-proof your processes. You want to find practical methods that are easy to use and useful for everyone.
Step 4: Everything should be documented
This can be done in many ways. They guide operators through the process step by step. Operators can follow work instructions according to current best practices.
Step 5: Your training programs can be adapted
Employees must be able to understand and follow the new procedures. Re-training existing workers may be necessary. You also want to ensure that the new operator training programs you create are based on your existing work.
Step 6: Continuously improve the standard
A common mistake is to believe that once you have established standardized work, it is done. You should instead strive to improve the standard. It is much easier to spot abnormalities and problems once a standard work process has been established. Root-cause analysis is performed for each problem.
Standardized work is not always perfected or final. It is a best practice and should be challenged daily with Kaizen.
Three basic forms used in Standard Work
In creating standard work, three basic forms are used. These forms are used by managers, engineers, and supervisors on the front lines to design the process, and by operators to improve their jobs.
Standard work example – Process Capacity sheet
This form calculates the machine’s capacityCapacity refers to the maximum amount of work, output, or a ... Learn More... in a linked set (often a single cell), to verify true capacityCapacity refers to the maximum amount of work, output, or a ... Learn More... and identify and eliminate bottlenecks. This form calculates factors such as machine cycle times and tool setup and change intervals. It also includes manual work times.
LEAN standard work example – Standardized Work Combination Table
This form displays the total time taken by each operator to complete a particular production sequence. It also shows walk time and machine processing times. This form is more detailed and provides a better process design tool than operator balance charts. This table allows for the calculation of operator work content and the interactionIn statistics, an interaction may arise when considering ... Learn More... between machines and operators in a process.
LEAN Standard work example – Standard Work Chart
This form displays operator movements and material locations in relation to the machine. It also shows the overall process layout. To ensure smooth operation, the form must show three elements that make up standard work: the current takt (and cycle) time for the job, the work sequence, and the required standard in-process inventory. As a visual tool for kaizen and visual management, standardized work charts are often displayed at workstations. They are constantly reviewed and updated in response to changes or improvements in the conditions of the worksite.
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