Standardized Work

Creating Continuous Flow

Process
Coaching Presented by:
Incorporated Brian D Krichbaum
 Standardized Work
Definition

A detailed and documented system in which

production workers both develop and follow a
repeatable sequence of tasks within a work
assignment. The standardized work sequence
represents the best practices for the operator to
follow in the completion of his/her job.

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Incorporated
 Standardized Work
Elements

Takt time – Demand Rate

Cycle Time – Production Time
Work Sequence

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Incorporated
 Standardized Work
Takt Time

Takt Time - the demand rate of production, the

rate at which we sell our product or service.
Takt is a German musical term which refers to
the pace, or drumbeat of a musical score. The
concept of takt keeps our activities on pace
much as the metronome keeps the musician on
the beat.

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 Standardized Work
The Tools

Process Instruction Sheets

Standardized Work Analysis Sheet (Cell Layout)
Time Observation Sheet
Operator Balance Chart
Standard Work Combination Sheet

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Incorporated
 Standardized Work
Process Instruction Sheets

Definition
Detailed, visual instructions written from the
perspective of the operator which detail the
sequence, methods, tools required and critical
to quality characteristics of an operation.

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Incorporated
 Standardized Work
Cell Layout
Definition
Detailed, visual representation of the location of
everything in the workcell, including
workstations, parts racks and storage areas,
and operators.
Used to plan the layout of cells, analyze the
amount of walking built into the process and to
institutionalize improvements

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 Standardized Work
Time Observation Exercise

Job Descriptions:
 Production Operators – Remove labels
from 3” x 3” blocks
 Packer – Pack boxes and maintain supplies
 Industrial Engineer – Conduct time studies

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 Standardized Work
Time Observation Exercise
Work Instructions
 Obtain Full Box of Blocks
 Empty Box – Place Blocks on Table
 Remove 1 blue label from each block
 Remove 1 yellow label from each block
 Remove 1 red label from each block
 Repack Box
 Return to storage area

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 Task/Process Being Observed Observer(s) Day/Time Of Observation

Observation Number Assigned Component

Time REMARKS
Step No. Task Component
1 2 3 4 5 6 7 8 9 10 11 12

Time For One Cycle Running Time

(cumulative)
Total
Time Time for each
Component

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Incorporated
 Standardized Work
Operator Balance Charts
Definition
A graphical representation of the times
required by each operator in a cell to
complete their individual work elements.
Operator balance charts are used to
distribute work and ensure work is being
completed near takt.

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 Standardized Work Combination Sheet
Part Number 98-097-654 Date Prepared 10-Mar-05 Daily Demand 231 Units

Part Name HT Injection Manifold Work Area Manifold Assembly Takt Time 117 Second
Work Sequence
Time
Operation Time (seconds)
Step Operation
Man Auto Walk 5 Sec 10 Sec 15 Sec 20 Sec 25 Sec 30 Sec 35 Sec 40 Sec 45 Sec 50 Sec 55 Sec 60 Sec 65 Sec 70 Sec 75 Sec 80 Sec 85 Sec 90 Sec 95 Sec 100 Sec 105 Sec 110 Sec 115 Sec 120 Sec

Obtain Manifold from

1 conveyor 15 5

2 Place in Wash Tub 10 1

Press Button to start wash
3 tub 1

4 Wash Tub Cycle 10 10

Obtain Manifold from
5 wash tub 6
Place manifold on work
6 bench 2 5
Obtain 4 valves from
7 stock area 2 5
Remove packaging from
8 valves 10

9 Place valves on manifold 8

Obtain screws and hand
10 tighten 7
Obtain torque wrench and
11 torgue to 50 ft lbs 3
Record torque values on
12 tracker 8

13 Mask off valve assembly 9

14 Aside to pallet 4
Move to conveyor to start
15 next assembly 5

95 10 21

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Incorporated
 Standardized Work
Equipment Guidelines
 Before investing in more equipment:
 Eliminate waste in the machine cycle
 Split apart tasks at the bottlenecks; use
more than one machine
 Install multiple machines at the
bottlenecks
 Create another cell
 When there are no other choices, operate the
bottleneck in a decoupled manner (batch, not
flow)
8. Ibid - page 63

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Coaching © 2008 Process Coaching Incorporated
Incorporated