Lean Concepts Inc. Establishing World Class Manufacturing Practices (Please Turn Off or Silence Cell Phones) John Veatch Lean Concepts Inc. 17710 Willowcreek Way Westfield, IN 46074 johnveatch@lean-concepts.com All Material Herein © 1998 Lean Concepts Inc. Revised 2010

Standardized Work

The Challenge of Change Where we are Where we want to be Comfort Fear Anger Anxiety Sabotage Loss of status Denial Blame Past Patterns WIIFM? (What’s in it for me?) “…no meaningful change occurs without chaos” Margaret Wheatley Wheatley is a professor at Brigham Young University in Provo, Utah, and president of The Berkana Institute, a research foundation working on the design of new organizations. She has also been a practicing consultant for some 20 years. Her latest book, co-authored with Myron Kellner-Rogers, is called A Simpler Way. Chaos Reject Accept

What is Standardized Work? The optimum combination of people, equipment, materials documented in time and space by the standard work combination sheet and the standard work sheet (layout and wip). The use of stable , repeatable , direct and unambiguous steps to achieve reliable output of processes and superior quality. Standard Work is the key to achieve takt time , one piece flow, and pull.

Why Should My Company Embrace Standard Work Kaizen will succeed only if you pay regular and productive attention to Standard Work. Team member choices are dramatically reduced, eliminating the “do it your own way”. Abnormal conditions are clearly defined and tracked. The flow of people, information, equipment and materials is choreographed to eliminate waste.

A Advantages of Standard Work Repeatable Processes. Operator Training. Repeatable Quality Improved Safety. Disadvantages of Standard Work

Takt Time Takt time sets the pace for Just-In-Time production. It is the amount of time allotted for the production of one unit based on the available time and demand. Takt Time Formula: TT = Daily Available Time Daily Demand

Standardized Work Objectives Establish and clarify the guidelines for manufacturing QUALITY, QUANTITY, COST, MANNING, INVENTORY, AND SAFETY Provide a tool for Kaizen YOU CANNOT MANAGE WHAT YOU DO NOT MEASURE WHERE THERE IS NO STANDARD, THERE CAN BE NO KAIZEN

Standardized Work Three elements Four Tools “Takt” time / Cycle time Work Sequence Standard WIP Four Tools Time Observation Process Capacity Standard Work Combination Sheet Standard Work Layout

The 7 Forms of Waste (Muda) T ransportation O verproduction M otion D efects W aiting I nventory P rocessing

Questions

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