standard work (sample slides) superfactory manufacturing excellence series lean overview 5s visual...

Standard Work (Sample Slides)Standard Work (Sample Slides)Superfactory Manufacturing Excellence SeriesLean Overview5S & Visual FactoryCellular ManufacturingJidokaKaizenPoka Yoke & Mistake ProofingQuick Changeover & SMEDProduction Preparation Process (3P)Pull Manufacturing & Just In TimeStandard WorkTheory of ConstraintsTotal Productive MaintenanceTraining Within Industry (TWI)Value Streams

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ContentsContents• Introduction• Background and History• Components and Implementation• Knowledge Check


IntroductionIntroduction• 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.


Components and ImplementationComponents 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


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


Standard WorkStandard 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 sequenceThe 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


Step 4: Standard Work SheetStep 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


Improving Standard WorkImproving 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


Maintaining Standard WorkMaintaining 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

standard work (sample slides) superfactory manufacturing excellence series lean overview 5s visual...

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