Standard Operations 09 / 16

Standard Work & Process of Standardization

World-Class Standards & Best Practices of Operational Excellence

© Lean & Mean Consulting. All rights reserved. 2016
2015
 LEAN Management Academy - Outline
Knowledge & Expertise / Editable Training Presentations / 16 Modules

World-Class Standards & Best Practices of Operational Excellence

© Lean & Mean Consulting. All rights reserved. 2016
Learning Objectives

1. Understand the importance of standardization in

Lean Production System

2. Identify the key benefits and applications of

standards and standard work

3. Acquire knowledge of standard work concepts,

principles and tools to maximize performance and
minimize waste

3
Contents

1. Introduction
2. Standardization
3. Standards
4. Standard Work
5. Implementing & Sustaining Standard Work
6. Improving Standard Work

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Module. 09

Standard Work / Process of Standardization

1
What Is Standard Work?
 Standard work is one of the most powerful but one of the most
underutilized of the lean tools.

 Documenting the current best methods, standardized work forms the baseline
for kaizen and continuous improvement.
 As the standard is improved, the new standard becomes the baseline for further
improvements, and so on.
 Improving standardized work is a never-ending process.

 Establishing standard work relies on collecting and recording data on a

few forms.

 These forms are used by engineers and front-line supervisors to design the
process and by operators to make improvements in their own jobs.
 In this workshop, you'll become familiar with these forms and why it will be
difficult to make your lean implementations “stick” without standardized work.

6
What Is Standard Work?

 Standard work establishes the best and most reliable

methods and sequences for each process and each worker

Materials and Machines Methods People Measurements

parts (equipment)

Feed in Ship to customers

materials

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Standard Work Forms the Baseline for
Continuous Improvement

Kaizen

A P
C D

Kaizen

A P A S Standardization
C D C D

A S Standardization
C D
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The Framework of Standardization

The practice of setting,

communicating, following, and
improving standards and standard
Standardization work

A set of work procedures that

establish the best and most
reliable methods and
Standard Work sequences for each process
and each worker

A rule or example that

provides clear explanations
Standards

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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

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 Ladder of Standardization

Direction of improvement
Step-by-step
progress to
higher levels of 6. Improvement of management methods: Information
standardization
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

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Documents in Manufacturing
Work Standards Standardized Work
• Work instructions • Process capacity table
• Operation drawings • Work combination chart
• Operation instruction sheets • Standardized work chart
• Process conditions sheets
• Quality control sheets
• Tooling layout drawings
• etc.

Job Instruction Work Study/Improvement

• Job breakdown sheet • Time study
• Cross training skills matrix • Motion study
• Operation instruction sheets • Work element analysis
• Etc. • etc.

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Standard Work Overview
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.

• Repetitive cyclical work

3 Requirements • High process and part quality
• Low equipment downtime

• Takt time
Actual Standard •
3 Elements Work sequence
Work in TPS • Standard work-in-process

• Process capacity table

3 Forms • Standardized work combination chart
• Standardize work chart

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.

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Module. 09

Standard Work / Process of Standardization

3
What is a Standard?

Standard – it is a formal, written definition of the

best knowledge and method of work,
recognized and depicted at any given
moment for satisfaction of customer
requirements.

Standard provides clear explanations!

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Standards
 Basic features of standards:
 Present the best, easiest and safest method of doing work
 Constitute the best method of preserving knowledge and
competence
 Constitute the benchmark for work evaluation
 Show the cause and effect relation
 Give basis for maintaining current level and development
 Are factual, simple and clear
 Constitute basis for training
 Are the basis for inspection and diagnosis
 Are the means to prevent mistakes and minimize variability

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Types of Standards

 Regulations  Process Standards

 Quality Standards  Manuals

 Specifications  Notices

 Technical Standards  Memos

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Three Steps to Establish Standards

1. Create the
standard

3. Improve the 2. Stabilize the

standard standard

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Step 1: Create the Standard

 Define the problem

 Identify abnormal conditions

 Define the standard required for normal performance

 Gain team agreement on the standard

 Implement the standard – communicate and train as needed

 Monitor and follow up

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Module. 09

Standard Work / Process of Standardization

4
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

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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

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Six Characteristics of Standard Work

• Clear
6 • Correct
• Concise
Characteristics
of Standard • Communicated
Work • Current
• Complete

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Standard Work Must be Clear
•Clear
6 •Correct
Characteristics •Concise
of Standard •Communicated
Work •Current
•Complete

 Standard work has to be clear so that it can be followed

correctly.

 What is clear to one person may not be clear to another.

 We need to ensure that users and auditors understand

standard work the same way.

 Extra jargon, verbosity, vague description or poor formatting

should be avoided.

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Module. 09

Standard Work / Process of Standardization

5
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

26
Three Elements of Standard Work

Standard
Work-In-Process
Inventory

Standard
Work Takt-Time
Sequence

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Three Elements of 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 work-in-process inventory

 The minimum number of parts, including units in machines, required to keep
a cell or process moving

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Module. 09

Standard Work / Process of Standardization

Standard Work Sequence
Good

Poor

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Four Steps to Standard Work

1. Create a Process Capacity Table

2. Create a Standard Work Combination Table

3. Create a Work Methods Chart

4. Create a Standard Work Chart

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Step 1: Process Capacity Table

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Step 4: Standard Work Chart: example

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Step 4: Standard Work Chart

 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

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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.

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© Lean & Mean Consulting. All rights reserved. 2016
36