Standardized Work Training Aid

ABC Game Facilitator Guide

 Room Set Up

Chair
Potential Trip Hazard
Table Team

Configured box
of assorted
pens
Flip
Chart

2
 Activity Introduction

The aim of this activity is to learn how to document a process using

the standard operation sheets.

The process produces one black ABC in capitals each cycle, on the
flipchart.

Draw the “standard” ABC on the flipchart as per diagram below.

Ea s e

Fig. 1
ABC 25 mm
80 mm

3
 Activity Introduction

I will run through two cycles of the process.

Write down exactly what you see in one cycle of the process.

I will say "start" at the beginning of the first cycle and "finish" at the
end of each cycle.

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 ABC Process: Job Detail Sheet
No. Work Element Key Point Ke y Po int Re as o n: S a fe ty Qua lity Ea s e Photo/Sketch
Pretend to trip over hazard on floor But avoid injury Ea s e

1 Stand up and walk to table Fig. 1

ABC 25 mm
80 mm
Select black flipchart pen from box To meet customer specification
2 Pick up pen and walk to flipchart

Write freehand as per standard. See Fig 1. To meet customer specification

3 Take off lid, write ABC, replace lid.

Put in configured place. To make it quick and simple to select next time.
4 Walk to table and put pen in box

Avoid trip hazard Avoid injury as walk and sit down

5 Walk to chair and sit down Check chair before sitting down

Repeat 1 - 5 one more time without

6 variation

5
 ABC Process: Standard Work Chart

Chair

1 Table Team

2
5
Configured box
4
of assorted
3
pens
Flip
Chart

6
 Team Activity: Identify process content

If the team need it, run through the cycle a third time.

Give the team time to write down what they have seen.

Ask each person how many steps they saw in one cycle.

Write up all the results on a flipchart.

Choose a team member who had about 11 steps and write their steps
up on the flipchart.

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Example list of process content

• Stand up
• Walk to the pens
• Select black flipchart pen
• Carry pen to flipchart
• Take the lid off
• Write ABC on the board
• Put pen lid back on
• Carry pen back to the table
• Place pen back in box
• Walk to the chair
• Sit down

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 Activity: Define work elements

In order to help us look at the process the same way, we follow

guidelines to help us define “work elements”.

A work element is an activity with a clear purpose that alters the

position or state of the employee, material or equipment. It has the
following features:

• A defined start and end point.

• Enough content for the time to be measured.
• If it needs more than 3 key points to add detail it has too much content.
• Walking is not shown as an element on its own.

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 Example elements

Apply this element classification to the list of steps on the flipchart.

The five elements:

1. Stand up and walk to table.
2. Pick up pen and walk to flipchart.
3. Take off lid, write ABC and replace lid.
4. Walk to table and put pen in box.
5. Walk to chair and sit down.

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 Team Activity: Time the elements

The next step is to time the elements.

Issue the stopwatches and explain how to use them.

Explain that we need to time each element and also the walking elements.

Perform one cycle of the process for the team to time.

Commentate to assist the team with the timings by saying start, split
(between each element and to separate out the walk times) and finally end.

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 Example element times

Example of the timed elements:

1. Stand up and 2 seconds

walk to table 3 seconds

2. Pick up pen and 2 seconds

walk to flipchart 4 seconds

3. Take off lid, write ABC and replaced lid 7 seconds

4. Walk to table and 4 seconds

put pen in box 2 seconds

5. Walk to chair and 3 seconds

sit down 2 seconds

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 Team Activity: Create Standardized Work
Chart
Fill in the chart heading boxes.

Fill in the working sequence steps and number them.

Draw a scale diagram of the process layout.

Add the number of each step to the diagram.

Connect the circles in sequence with the appropriate line.

Indicate any safety or quality points.

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 Example Standardized Work Chart
Organisation ACME
Created By C Brown
Area Training Room
Part Name/Number ABC Standardised Work Chart Issue Date 23/10/2007
Job From: Stand up and walk to table Issue Number 1
Content To: Walk to chair and sit down Takt Time -
No. Working Sequence Steps

1 Stand up and walk to table

2 Pick up pen and walk to flipchart Chair
3 Take off lid, write ABC and replace lid
4 Walk to table and put pen in box
5 Walk to chair and sit down
1 Table

2
5
Configured box
4
of assorted
3
pens
Flip
Chart

Employee Movement: Material Movement:

Standard In-Process Stock
Safety Quality Check Cycle Time
Symbol Total Number In Cell

- 29 seconds

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 Team Activity: Create Job Detail Sheet

 Fill in the chart heading boxes.

 Write in and number the work elements.

 Add relevant key points.

 Complete the key point reason column.

 Add photos or sketches.

 Indicate what PPE is required and fill in the key preparation activities box.

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 Example Job Detail Sheet
Organisation ACME
Area Training Room Created By C Brown
Part Name/ Number ABC
Job Detail Sheet
Working Sequence Step Steps 1 to 5 Issue Date 23/10/2007
Operation / Process No. - Issue Number 1
Initial Creation Date 23/10/2007 Takt time -
No. Work Element Key Point Key Point Reason S a fe ty Qua lity Ea se Photo/Sketch

Avoid trip hazards To avoid injury

1 Stand up and walk to table
Ea s e

Select black flipchart pen from To meet customer Fig. 1

2
Pick up pen and walk to box specification ABC 25 mm
flipchart 80 mm

Write freehand as per standard. To meet customer

Take off lid, write ABC, See Fig 1. specification
3
replace lid.

To make it quick and simple to

Walk to table and put pen Put in configured place.
4 select next time.
in box
Avoid injury as walk and sit
Avoid trip hazard
down
5 Walk to chair and sit down
Check chair before sitting down

Rev. Date Content of revision

Eye Protection Ear Protection Foot Protection Hand Protection Other PE Key Preparation Activities

PPE Required: (Write specification)

Set up training room

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 Team Activity: Create Standardized Work
Combination Table
Fill in the chart heading boxes.

Write in and number the work elements.

Fill in the time for each work element.

Total the time in each column. Set the scale.

Draw in each work element.

Work out the cycle time and fill it in.

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 Example Standardized Work
Combination Table
Organisation ACME
Created By C Brown
Area Training Room
Standardised Work
Part Name/ Number ABC Issue Date 23/10/2007
Combination Table Issue Number
From: Stand up and walk to table 1
Job Content
To: Walk to chair and sit down Takt Time -
Time Element Time Unit: seconds
No. Work Element
5 10 15 20 25 30
Manual Auto Wait Walk

Stand up and walk to

1 2 3
table
Pick up pen and walk Cycle time = 29 s
2 2
to flipchart 4
Take off lid, write
3 7
ABC and replace lid
Walk to table and put
4 2
pen in box 4
Walk to chair and sit
5 2
down 3

Key:
Totals 15 14 Manual Walk
Auto Waiting
Cycle Time 29

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 Activity Review

Ask the team to look at the three sheets and:

Summarize the purpose of each document.

Give examples on how they can be used to identify improvements.

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