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Standard Work

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Standard Work What is Standard Work

Definition AStandard Workis a combination of men,

materials and machine to carry out production ina maximally efficient way.

Standard Work is different from Standard

Operation Procedure

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Standard Work Functions of Standard Work (1/2) (1/2)

(1) Training materials for newcomer

(2) Tools for management

a) Design of Production Line b) Manpower Requirement plan

c) Equipment Requirement plan

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Standard Work Functions of Standard Work (2/2) (2/2)

d) On-Hand WIP plan

e) Target of production speed

f) Visual Management

(3) Tool for Kaizen

No improvement can take place without Standard Work being

defined first.

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Standard Work Elements of Standard Work

(1) TAKT Time

(2) On-Hand Work-In-Process

(3) Operator Work Sequence

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Standard Work TAKT TIME

Definition Takt Time = Target Time = T.T

Example :

Working Time per day Units demand per day T.T =

8 Hours x 3600 sec.T.T =1000 Units/day

= 28.8 Sec/Unit

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Standard Work On-Hand Work-In-Process

Meaning Refers to theminimum WIP needed to perform

repetitive operations, e.g., parts mounted to

machines, parts on conveyors, parts needing

time to cool.

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Standard Work Operator Work Sequence

Meaning The order of operations in which an operator carries

objects, mounts them on machines and removesthem etc..

This should be distinguished from theproduct

process sequenceaccording to which a product ismade, which will influence the number of On- Hand

WIP.

S d d k

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Standard Work Forms of Standard Work

(1)Value Stream/Process Flow Chart

/(2) Time Measurement Sheet (3) Process Capability Sheet (4) Standard Work Combination Sheet

(5) Process/Cycle Time Chart (6) Standard Work Sheet

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Standard Work Symbols for Value Stream/ProcessFlow Chart /(1/4)

Customer

Supplier Material push flow

Material pull flow by withdraw kanban

Material pull flow by production kanban

Material pull flow by signal kanban

W

P

S

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Standard Work Symbols for Value Stream/ProcessFlow Chart /(2/4)Information flow

Buffer Inventory

Safety Inventory

Production Cell

Leveling (Heijunka)

Supermarket

B

S

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Standard Work Symbols for Value Stream/ProcessFlow Chart /(3/4)

Kanban Post

Production Planning Control

Material, before process

Finished Goods, after process

Process and sequence number

ppc

1

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Standard Work Symbols for Value Stream/ProcessFlow Chart /(4/4)

Self 100% Inspection

Walking operation

QA Sampling Inspection

Waiting/Storage /

Combine Operation

With inspection

2

4

3

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Standard Work Time Measurement and Calculation (1/2)

HT = Human Work Time MT = Machine Work Time PBS = Process Batch Size m = Number of station of

specific process

OT = Overlapping Time

between HT and MT

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Standard Work Time Measurement and Calculation (2/2)

PT = Process Time PT = HT+MT-OT

CT = Cycle Time CT = PT /PBS / m

When PBS = 1 piece

m = 1 station

Then CT = PT

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Standard Work Procedure of Standard Work (1/2) (1/2)

(1)Value Stream/Process Flow Chart by product(2) Time Measurement by process(3) Process Capability Sheet (4) Standard Work Combination Sheet(5) Decide On-Hand WIP Quantity

St d d W k

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Standard Work Procedure of Standard Work (2/2) (2/2)

(6) Trial Operation by supervisor (7) Correction if necessary (8) Standard Work Sheet (9) Maintain Standard Work (10) Kaizen Standard Work

S d d W k

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Standard Work Standard Work and Kaizen (1/10) (1/10)

The Need of Kaizen No Standard Work = No Kaizen

Standard Work : Decided by supervisor to express

his/her expectation of operation in

the production line.

St d d W k

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Standard Work Standard Work and Kaizen (2/10) (2/10)

Pre-Standard Work : Write down current operation situation.

Standard (Expectation)()

Difference (Problem) :()

Need of Kaizen

Actual (Current)()

St d d W k

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Standard Work Standard Work and Kaizen (3/10) (3/10)

T.T

CT >TT CT

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Standard Work Standard Work and Kaizen (4/10) (4/10)

Step of Kaizen Start from Operation Kaizen

Later do Equipment Kaizen

Operation Kaizen Spend little money, by eliminating

MUDA first

Use the wisdom of own company

Standard Work

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Standard Work Standard Work and Kaizen (5/10) (5/10)

Equipment Kaizen Spend lot of money,

Hide MUDA

The wisdom from equipment supplier

St d d W k

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Standard Work Standard Work and Kaizen (6/10) (6/10)

Sequence of Operation Kaizen Shorten Distance Relayout of By Flow LineOf Transportation Machine Production Change operation Eliminating By StandardSequence/ Waiting Muda, WorkCombination Work to T.T/ TT

Standard Work

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Standard Work Standard Work and Kaizen (7/10) (7/10)

Sequence of Operation KaizenKaizen in Reduce Human By MotionOperation Work Time EconomyMotion Jidoka

Standard Work

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Standard Work Standard Work and Kaizen (8/10) (8/10)

The Cycle of Kaizen Standard Work before Kaizen

Pre- Standard Work

The need of Kaizen

Find out areas of Muda and problem

Dig out the root cause

Standard Work

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Standard Work Standard Work and Kaizen (9/10) (9/10)

The Cycle of Kaizen Implement Kaizen Actions

Standardization

Issue Standard

Work SheetThis is my ideal Production line

Standard Work

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Standard Work Standard Work and Kaizen(10/10) (10/10)

Kaizen Categories by Standard Work

Reduce Manhours

Reduce WIP Quantity

Reduce Defects

Increase Productivity

Reduce Space