Standardised Work: Creating Workpackages - PowerPoint PPT Presentation

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Standardised Work: Creating Workpackages

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  1. Standardised Work: Creating Workpackages

  2. The 2 Routes to Workpackage Implementation Route A Route B Route A • Workpackages Not In Place • Implementation Involves: • -Data analysis & capture • Line balance creation • Calculation of Takt Time • Balancing to Takt • Alignment to Programme Plan • Inclusion into Performance Management System • Use when: • There’s a requirement to match pace of production to customer demand • Trying to create man/material flow Route B • Workpackages In Place • Implementation involves: • Calculation of Takt Time • Rebalancing to suit new Takt • Re-alignment to Programme Plan • Inclusion into Performance Management System • Use when updating Workpackages: • Rate change • Level of resource change • Removal of Waste/Reduction of NVA Workpackages in Place? No Yes Identify Work Sequence Identify Categories of Work Line Balance Board Creation Calculate Takt Time Apply To Current State Line Balance Align To Programme Plan Common Steps Performance Management

  3. Route A: Identify Work Sequence & Categories of Work Discipline ‘B’ Discipline ‘C’ Critical to WkPkgs Critical to WkPkgs Discipline ‘A’ Build, Time, Support, Other… 1. Map the current operational processes - Identify ‘who does what & when’ (Tasks & Times) - Identify Critical Build Sequence - Identify the categories of work - Value Added, Non-Value Added & Waste Activities • 2. Collect issues with current processes • - Build (Sequence of, process interference etc) • - Time (questioning the current package allowance etc) • - Support (Engineering, Quality, Support, Operations etc) • - Other (anything else...) • Create Tactical Implementation Plans to resolve issues

  4. Route A: Line Balance Board Creation • 1. Transfer operational processes onto strips • Opportunity to discuss & resolve ‘Build’ issues • Use Coloured magnets/paper strips to show the categories of work (VA, NVA, Waste)

  5. Route A/B: Calculate Takt Time Takt = Total Time Available* (* minus agreed losses – TimeTotal Customer Demand lunch, breaks etc) Example: Takt = 300 Hours/Month* (* minus agreed losses – Time12 Units/Month lunch, breaks etc) = 25 Hours • 1. Calculate the ‘drumbeat’ for production • Calculate the frequency at which the production system must produce quality product • In the above example, a Unit must be produced every 25 hours to satisfy the requirement of 12 Units/Month

  6. Route A/B: Apply Takt Time to Current State Line Balance Time Time Operators Takt Time Operators Takt Time Time Operators Re-Balance • 1. Rebalance processes to suit Takt Time • Maintain critical build sequence & re-balance ‘floating’ tasks • Identify manning & capacity requirements to work to Takt Time • 2. Create Workpackage documentation • Create workpackage documentation according to team/workstation requirements • Agree a suitable management time frame for updating of status (i.e. 1 hour, 1 shift etc) WP4 WP5 WP6 WP1 WP2 WP3

  7. Route A/B: Align to Programme Plan Workstations Date Workpackages Manning Levels 1. Create high-level Workpackage Schedule document - Visually represent where & when each Workpackage is scheduled to be completed - Shows level of resource required when working to Takt Time

  8. Route A/B: Performance Management TEAM BOARD : STATION 99 QUALITY COST DELIVERY PEOPLE TAKT ADHERENCE SKILLS MATRIX PRODUCTIVITY SCRAP CONCESSIONS / DEFECTS CURRENT DISRUPTIONS ATTENDANCE ISSUES RESOLVED HEALTH & SAFETY PREVIOUS LOCAL INFORMATION SIGN OFF 5C SHIFT : TEAM LEADER : PRD File • 1. Display Workpackage documentation at the place of work • Increase Visual Management at the workstation • Process ownership clear with key stakeholders involved • Workpackage Status to be updated at the agreed management time frame interval • Issues regarding workpackage adherence to be raised, resolved & escalated if necessary from this location

  9. Route A/B: Workpackages Created Workpackages in Place? No Yes Identify Work Sequence Identify Categories of Work Line Balance Board Creation Calculate Takt Time Apply To Current State Line Balance Align To Programme Plan Performance Management