Lean Standard Work by Operational Excellence Consulting

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Standard Work:

Standard Work Create, Stabilize, Improve

Learning Objectives:

Learning Objectives Understand the importance of standardization in Lean production Identify the key benefits and applications of standards and standard work Acquire knowledge of standard work concepts, principles and tools to maximize performance and minimize waste Copyrights of all the pictures used in this presentation are held by their respective owners.

Contents:

Contents Introduction Standardization Standards Standard Work Implementing & Sustaining Standard Work Improving Standard Work NOTE: This is a PARTIAL PREVIEW . To download the complete presentation, please visit: http:// www.oeconsulting.com.sg

What Is Standard Work?:

What Is Standard Work? Standard work establishes the best and most reliable methods and sequences for each process and each worker Materials and parts Measurements People Methods Machines (equipment) Feed in materials Ship to customers

What Is Standard Work?:

What Is Standard Work? Written for operators or the frontline staff Kept visible in the the work area, e.g. near an operator’s machine or work station Documented using lots of visuals and pictures instead of narrative text A reference for use in the real workplace outlining the actions to be performed, any needed tools, materials, work flow, and work pace expected at that position

What Standard Work IS NOT:

What Standard Work IS NOT ISO 9001, cGMP or other regulatory standards Static – once and for all – documentation of how to do a job Restrictive – like a soldier’s “rules of engagement” A process which stifles creativity and innovation Created by leaders for operators or frontline staff

Standard Work Creates Stability & Consistency in a Lean Production System:

Standard Work Creates Stability & Consistency in a Lean Production System Stability Heijunka Standardized Work Kaizen Just-In-Time Continuous flow Takt time Pull system Flexible workforce Jidoka Separate man & machine work Abnormality Identification Poka yoke Visual Control Goals: highest quality, lowest cost, shortest lead times Involvement

Standard Work Assures Quality & Prevents Defects From Happening:

Standard Work Assures Quality & Prevents Defects From Happening Process Capability Standard Defects Defects

PowerPoint Presentation:

“Where there is no standard, there can be no Kaizen.” - Taiichi Ohno Toyota Motor Company

Standard Work Forms the Baseline for Continuous Improvement:

Standard Work Forms the Baseline for Continuous Improvement

Benefits of Standard Work:

Benefits of Standard Work Clarifies the process Documents the best way to do a job Ensures operating consistency Expedites employee training Provides the baseline for improvement

The Framework of Standardization:

The Framework of Standardization The practice of setting, communicating, following, and improving standards and standard work A rule or example that provides clear explanations A set of work procedures that establish the best and most reliable methods and sequences for each process and each worker Standardization Standard Work Standards

What is Standardization? :

What is Standardization? Standardization is the practice of setting, communicating, following, and improving standards A standard provides the baseline upon which to measure the results of continuous improvement activities If better results are obtained with the improved process, then the standard can be changed The process of continually improving the standards is the path to reliable methods Everyone must practice the standard consistently before standardization truly exists

Ladder of Standardization:

Ladder of Standardization 6. Improvement of management methods: Information 5. Standardization of objects: Materials 4. Building standards into equipment: Production equipment, computers, etc. 3. Standards for jigs, tools and alarm devices: Measurement 2. Standards manuals to clarify work sequences: Methods 1. Procedures explained by veteran workers: People Step-by-step progress to higher levels of standardization Direction of improvement

Standard Work Overview:

Standard Work Overview 3 Requirements 3 Elements 3 Forms Actual Standard Work in TPS Repetitive cyclical work High process and part quality Low equipment downtime Process capacity table Standardized work combination chart Standardize work chart Takt time Work sequence Standard work in process Definition: A document centered around human motion that combines the elements of a job into the most effective sequence without waste to achieve the most efficient level of production. If these forms and conditions are not met then it is not true standard work. The task is probably best suited by some form of work instruction or other standard.

Standard Pig Game:

Standard Pig Game

What is a Standard?:

What is a Standard? A standard is a rule or example that provides clear explanations Continuous improvement methods depend on identifying, setting and improving standards Standards form the baseline for all improvement activities and breakthrough goals you strive to achieve

Key Features of Standards:

Key Features of Standards Standards represent the best, easiest, and safest way to do a job Standards offer the best way to preserve know-how and expertise Standards provide a way to measure performance Standards show the relationship between cause and effect Standards provide a basis for both maintenance and improvement

The Lack of Standards Creates Waste and Frustrations:

The Lack of Standards Creates Waste and Frustrations Which dial turns on the burner? Which is the right plug?

A Good Standard Should Identify Normal vs. Abnormal Condition:

A Good Standard Should Identify Normal vs. Abnormal Condition Adding a simple gauge label enables any employee to easily detect abnormalities at a glance and at a distance . Without the label, only a trained inspector would know if the temperature or pressure setting is correct. Drive tension guides help operators inspect for proper tension on the drive system. Using red and green color blocks, these visuals indicate when a chain or belt needs to be tightened or replaced. Placing a green and red striped label behind the oil sight tube helps operators quickly detect when oil levels are too high or too low.

Three Steps to Establish Standards:

Three Steps to Establish Standards

What is Standard Work?:

What is Standard Work? 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 aims to maximize performance while minimizing waste in each person’s operation and workload Standard work is the fluctuating level of optimum work to be done by people and machines each day to meet customer demand

Standard Work:

Standard Work Prerequisites for standard work 5S and visual controls Quick changeover Mistake-proofing Total productive maintenance Human automation Cellular manufacturing Pull production with kanban Line balancing

Six Characteristics of Standard Work:

Six Characteristics of Standard Work Complete Clear Correct Concise Current Communicated Characteristics of Standard Work

Ideal Conditions for Standard Work:

Ideal Conditions for Standard Work Work point of view Work is centered around human motion Work is done the same way each time Small variation in work content Equipment point of view Minimal trouble with machines Minimal fluctuation in production volume Quality point of view Minimal trouble in process quality Minimal trouble in parts and material

Three Elements of Standard Work:

Three Elements of Standard Work

PowerPoint Presentation:

If Takt Time and Cycle Time are not the same, an imbalance exists in the operating system If Cycle Time is less than or equal to Takt Time, production will satisfy customer demand If Cycle Time is greater than to Takt Time, production cannot satisfy customer demand Takt Time and Cycle Time A B C D E Step A1 Step B1 Step A2 Step B2 Step A3 Step B3 Step C1 Step C2 Step C3 Step C4 Step C5 Step E1 Step E2 Step E3 Step E4 Step E5 Step D1 Step D2 Step D3 Step D4 Step D5 Operators Takt Time (60 sec) Step A4 10 20 30 40 50 60 0

Four Steps to Standard Work:

Four Steps to Standard Work Create a Process Capacity T able Create a Standard O perations C ombination C hart Create a Work Methods Chart Create a Standard W ork Chart

Maintaining Standard Work:

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

Methods to Increase Productivity:

Methods to Increase Productivity Current 1 Man 1 Machine 100 Units 1 Hour Future 1 Man 1 Machine 120 Units 1 Hour Focus o f TPS

True versus Apparent Efficiency:

True versus Apparent Efficiency Before we made 100 parts with 10 people. Now we can make 120 with the same manpower ! A real improvement would be to make 100 parts with only eight people on the production line! But we only need 1 00 parts to meet demand. The rest is over-production

Procedure for Kaizen:

Procedure for Kaizen Text Text Text Text Text Text 2. Analyze the Current Situation 3. Generate Original Ideas 6. Evaluate the New Method 5. Implement the Plan 1. Clarify the Goal 4. Develop Implementation Plan

Kaizen is Endless:

Kaizen is Endless Current State Standardize Standardize Kaizen Kaizen Kaizen P D C A Kaizen ( 改 善 ) = Continuous Improvement Future State

About Operational Excellence Consulting:

About Operational Excellence Consulting

About Operational Excellence Consulting:

About Operational Excellence Consulting Operational Excellence Consulting is a management training and consulting firm that assists organizations in improving business performance and effectiveness. The firm’s mission is to create business value for organizations through innovative operational excellence management training and consulting solutions. OEC takes a unique “beyond the tools” approach to enable clients develop internal capabilities and cultural transformation to achieve sustainable world-class excellence and competitive advantage. For more information, please visit www.oeconsulting.com.sg

To download this presentation, please visit us at: www.oeconsulting.com.sg:

To download this presentation, please visit us at : www.oeconsulting.com.sg END OF PARTIAL PREVIEW

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