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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

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

contents
Contents
  • Introduction
  • Background and History
  • Components and Implementation
  • Knowledge Check

© 2007 Superfactory™. All Rights Reserved.

introduction
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.

components and implementation
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.

types of standards
Types of Standards
  • Regulations
  • Quality Standards
  • Specifications
  • Technical Standards
  • Process Standards
  • Manuals
  • Notices
  • Memos

© 2007 Superfactory™. All Rights Reserved.

standard work6
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.

step 4 standard work sheet
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.

improving standard work
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.

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

© 2007 Superfactory™. All Rights Reserved.