ADq IK Lean Training Standard Work Goutam Kr

ADq. IK Lean Training Standard Work Goutam Kr Ghosh Dated: 30 -06 -18 1

ADq. IK Agenda § § § What is it? What’s it for? How does it work? When do you use it? What’s an example? 2

ADq. IK What is it? Standardize work: 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. § Standard work represents the best, safest, and easiest way to do a job 3

ADq. IK What’s it for? § Standard work allows an organization to: § § § Create consistency and predictability Preserve know-how and expertise Prevent recurrence of errors Improve staff satisfaction and productivity Improve patient and physician satisfaction 4

ADq. IK How does it work? § Standard work is a documented record of how to do a job § It must be followed by all those performing that particular task § All associates § All shifts § Creating standard work involves several steps 5

Steps to Create Standard Work § § § ADq. IK Evaluate the current situation Identify areas of opportunity Modify the existing process Quantify improvements Implement new standard work 6

ADq. IK Evaluate Current Situation § To implement standard work, the current process needs to be understood § Direct observation is the best way to know the current process (Videography of 10~20 cycles and analysis ) § Don’t rely on procedures § Don’t rely on memory or brainstorming § This process frequently follows a mapping exercise 7

ADq. IK Evaluation (cont. ) § There are several tools to assist in the observation of the current process § § § Standard work sheets Time observation sheets Combination sheets Loading diagrams Many are best used for routine, repetitive tasks 8

ADq. IK Evaluation tools Standard Work Sheet Visually shows layout and work sequence 9

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ADq. IK Evaluation tools § § Time Observation Sheet Used to gather data on time duration of operation elements Three key steps § Identify work elements § Determine observation points § Time 11

ADq. IK Identify work elements. How to write your name on a Board 1. Stand up 2. Go to the Board 3. Pick up the marker by right hand 4. Open the marker by left hand 5. Write your name by right hand 6. Put down the marker 7. Return to chair 8. Sit down 12

ADq. IK Work Element sheet Work Elements Photos to defined the steps: 13

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ADq. IK Evaluation tools Combination Sheet § Helps make obvious the relationship between workers and machines - - the timing of operations performed in one cycle by one team member 17

ADq. IK Standard Work Combination Table - Definition The Standard Work Combination Table combines human movement and machine movement based on takt time and is used as a tool to determine the range of work and work sequence for which a team member is responsible. 18

ADq. IK Standard Symbols The four basic symbols used in Standard work combination tables are: Manual Automatic Walking Waiting 19

ADq. IK HOW TO DISPLAY WORK ON THE STANDARDISED WORK COMBINATION TABLE Manual Work Takt Time Walk Automatic Cycle Wait 20

ADq. IK HOW TO DISPLAY WORK ON THE STANDARDISED WORK COMBINATION TABLE Returning to the same process. TT 1 2, 4 3, 5 21

ADq. IK Issue date 30/09/99 Part Number / Name STANDARDISED WORK COMBINATION TABLE Manual Automatic Group Leader 123 ABC / Widget LH Qty / shift: 169 Walking Process Machine and sub Takt Time: 162 Available time: 480’ Supervisor Cycle time Waiting assembly Department: Machine. Prod/Engineer WORK SEQ’ OPERATION TIME MAN AUTO WALK 1 2 Select part A 2 Set into M/C 1 10 3 Start machine 1 84 4 5 Select part B 2 Set into jig 9 6 Select part C 2 7 Fit C to B 15 8 Set C/B to m/c 2 11 9 Start m/c 1 41 10 Remove A from m/c 15 7 11 Set A to jig 12 Remove C/B from m/c 5 15 13 Screw C/B to A 14 Check torque 8 15 Put in finished bin TOTALS 2 5 10 15 20 25 30 35 40 45 OPERATING TIME IN MINUTES 50 55 60 65 70 75 80 85 90 95 CT TT 105 115 125 135 145 155 100 110 120 130 140 150 160 3 2 2 3 3 3 2 5 Operator 129 95125 34 Wait time 33 22

ADq. IK Evaluation tools Loading Diagram Visual display of cycle time observations 23

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ADq. IK Evaluations § For duties that are less frequent, evaluations can be done more informally § You can create your own tool for evaluating the current process as needed § Time, motion, frequency, and interruptions are the most commonly-used evaluation criteria 25

ADq. IK Human work and Machine work The key notion for the elimination of waste and the effective combination of work on the shopfloor is the separation of machine work and human work. When we observe the work in which operators handle machinery, then that work can be classified into machine or human work. Understanding the separation of human and machine work is the basis for understanding the interface between these two elements. If operators are merely observing the machine working then this is the waste of “Waiting” and should be eliminated. 26

ADq. IK Human work This refers to work that cannot be completed without human effort. For example, § picking up materials § putting materials onto a machine § operating the controls of a machine § manual slaving etc. 27

ADq. IK Machine work This refers to work or incidental work that equipment, which has been started by human hand, automatically performs operations. § Milling § Auto riveting / bolting § Auto inspection (Hole probes) 28

ADq. IK Man- Machine Chart Man- Machine chart Project Name: OIL PUMP ASSEMBLY Tracking No: A 481 S. No Station Name Stn #10 - SA 11 Dowell pressing Assembly Stn #20 - SA 22 Shaft pressing Assembly Stn #30 - SA 33 Gear pressing Assembly 12 10 Stn #40 -SA 4 4 Clearance 10 checking Assembly 7 3 3 Stn #50 - Final 20 0 3 Assembly Stn #60 - DFCE 9 40 3 Checking Stn #70 -Free rotation & Flow 16 35 12 Testing Stn #80 -Tracebility 4 4 2 Marking ∑manual 5 6 7 8 ∑Automatic 0 0 Wait Auto Load /unload Walk Manual Total Mannual Machine time 15. 00 7 -3 23. 00 0 37 12. 00 43. 00 0 23 28. 00 47. 00 6. 00 2 112 148 - 15. 00 32. 00 0 - 15. 00 17. 00 0 - 15. 00 2. 00 GOTO NEXT 2 - 13. 00 34. 00 0 - 23. 00 11. 00 GOTO NEXT 11 - 12. 00 35. 00 0 NMCT 28. 00 7. 00 0 6. 00 127. 00 Total Waiting 10. 00 0 0 OPERATOR-3 Booked Free 13. 00 4 OPERATOR-2 13. 00 15. 00 7 NMCT OPERATOR-1 13. 00 15. 00 7 47. 00 NMCT Waiting time 2. 00 11 14. 00 1. 00 29

ADq. IK Identify areas of opportunity § There are many ways to identify areas for opportunity § 7 forms of waste § Spaghetti diagrams § Value added vs. non-value added activities(VA/NVA) § These methods highlight steps in the process that can be modified or eliminated 30

ADq. IK Quantify Improvements § Once opportunities are identified, changes to the work processes can be § § tested, evaluated, and selected Improvements should be measured in a live environment to ensure that they work and that they are an improvement The new standard work can now be documented and implemented 32

ADq. IK Implement § To implement new standard work, it must first be documented § Write it down § Next, the best way to hand out or display the new process should be determined § § Checklist? Photos? Posted in work area? Index cards? 33

ADq. IK Implement § Next, the best communication and training methods should be selected § Who? § How? § When? § Measurements should be in place § A method for ensuring that the new standard work is being used should be developed 34

ADq. IK When do you use it? § Standard work should be used for any task that is part of a process § In other words, all the time § When people depend on each other, standard work can make any work process easier, more predictable, and less prone to error 35

ADq. IK Questions? 36