IENG 451 Standardized Work

Benefits of Standardization – Process stability – stability means repeatability – Clear stop and start points for each process – Organizational learning – Employee involvement and poka-yoke (error proofing) – Kaizen – continuous improvement – Training

Sources of Instability Quality problems with incoming parts Problems with machines, jigs Parts shortages Waiting for a part Safety problems

Elements of Standard Work

Work sequence – Pick up part – Walk to machine – Place part on machine – Machine process part – Take part to next machine

Elements of Standard Work In-process stock – Minimum number of unfinished parts required for operator to complete the process without standing in front of a machine – Quality checks require additional in-process – Temperatures must fall for next operation (more) – Machinery cycles automatically (more)

Production Capacity Chart No Name M/C Man Time Mach Time To comp. Inter changes Capacity Time to change Basic Operation Time Tool Changes 3 MIL 1764 Machine face

Standard Work Table

Standard Work Chart

Job Element Sheets

Line balancing Station time Station time

Overall vs Individual Efficiency Goldratt – Drum, Buffer, Rope – Identify bottlenecks – Exploit bottlenecks – Elevate bottlenecks – Baseball cap factory

Standardized Work and Kaizen Guidelines for economy of motion (IE 311, 321) Guidelines for layout Guidelines for tools/jigs

Standardized Work and Kaizen Guidelines for economy of motion (IE 311, 321) – Hand movements symmetrical and current – Light work – Done in a strong circle – Keep hands free Guidelines for layout Guidelines for tools/jigs

Standardized Work and Kaizen Guidelines for economy of motion (IE 311, 321) Guidelines for layout (IE 471, 475) – Use gravity – Horizontal vs vertical movement – Place tools and materials for easy access – U-cells Guidelines for tools/jigs

Standardized Work and Kaizen Guidelines for economy of motion (IE 311, 321) Guidelines for layout (IE 471, 475) Guidelines for tools/jigs (IE 475) – Eliminate manual holding – Use ergonomic tools – Combine tools where possible

Common Layouts Job Shop Cells Assembly Line Strategies – Chase – Level – Mixed