STANDARDIZED OPERATIONS METHODS SEQUENCE Standardization is the road

STANDARDIZED OPERATIONS (METHODS & SEQUENCE) “Standardization is the road to continual improvement. ” W. E. Deming, July 15, 1992 QSB WORKSHOP REV. 112404 1 General Motors Corporation. All rights reserved.

STANDARDIZED OPERATIONS PROVIDES A FOUNDATION FOR: • • a lean organization. identifying value added tasks. an efficient production sequence. continuous improvement. reduced variation within a process. waste reduction, problem solving and quality control. auditing operator conformance to work instructions (Layered Audit*). • ensuring operators are consistently performing the same tasks and procedures. QSB WORKSHOP REV. 112404 2 General Motors Corporation. All rights reserved.

STANDARDIZED OPERATIONS (Example) WORKSHEET & LAYOUT WORK ELEMENTS OPERATOR MOVEMENT OPERATION CYCLE TIME QSB WORKSHOP REV. 112404 3 General Motors Corporation. All rights reserved.

STANDARDIZED OPERATIONS WORKSHEET & LAYOUT WORK ELEMENTS • • BENEFITS WHEN DISPLAYED: Operations performed same way every time. Reduces the risk of omitting components. Quality checks and frequency are indicated. Process improvements easily identified. • • OPERATOR MOVEMENT Training is simplified and consistent. Reminds operator of correct sequence. Alerts operator to safety concerns. Assures operator is following approved process (Layered Audits). Assures leadership operation is running as approved. Operator knows if equipment is showing signs of wear. Machine and operator hand work and walk time separated. Quality checks are included. QSB WORKSHOP REV. 112404 4 OPERATION CYCLE TIME General Motors Corporation. All rights reserved.

• Multi-disciplinary team(s) shall identify and list all operations to implement standardized work. Examples of how to prioritize: - Customer Quality Concerns Necessity for a Defined sequence or method of work Off-line Rework High RPN Employee Flow-through • Multi Disciplinary teams shall develop standardized work instructions which shall be posted at the operation. • Impacted and new employees shall be trained in the use of Standardized Work (Standard Operator Training*). • Any operation that shipped a non-conformance due to a failure to adhere to Standardized Work Instructions shall be verified through Layered Audits*. • Multi-disciplinary team(s) shall continuously develop and improve standardized work instructions. QSB WORKSHOP REV. 112404 5 General Motors Corporation. All rights reserved.

(Example) Standardized Operations Worksheet And Layout OPERATION: FROM: ______________ QUANTITY PER SHIFT: _______ TO: _______________ STEP NO. WORK ELEMENT STANDARD IN- ELEMENT TIME HAND WORK MACHINE SHIFT: ____ PROCESS STOCK WALK Q CUSTOMER CYCLE TIME: ________ OPERATOR CYCLE TIME: ________ QUALITY CHECK C CRITICAL OPERATION SAFETY Standardized Operations Worksheets and Layout shall include: - Work Elements - Operator Movement - Operation Cycle Time WORKSTATION AREA DRAWN TO SCALE TOTAL QSB WORKSHOP REV. 112404 6 General Motors Corporation. All rights reserved.

(Example) QSB WORKSHOP REV. 112404 7 General Motors Corporation. All rights reserved.

(Example) QSB WORKSHOP REV. 112404 8 General Motors Corporation. All rights reserved.

STANDARDIZED OPERATIONS SUMMARY Organizations shall… ü develop and implement standardized work instructions using multidisciplinary teams. ü post standardized work instructions at all operation ü train impacted and new employees in use of standardized work instructions (Standardized Operator Training*). ü insure that standardized worksheets include Work Elements, Operator movements and Operation cycle time. ü continuously develop and improve standardized work instructions based on ongoing quality performance. QSB WORKSHOP REV. 112404 9 General Motors Corporation. All rights reserved.