1. Work Measurement and Lean Application
You cannot manage if you do not measure!!

2. Continuous Improvement
What is work?
Any activity that consumes resources and creates value or non-value added for the customer
Identify
Map the AS-IS
Create Flow
Collect Data
Analyse data
Improve
Continuous Improvement

3. What is work measurement?
Is the application of techniques designed to establish the time for a qualified worker/process to carry out a task at a defined speed

4. Work Measurement Methodology
Select
Work to be studied
Record
Relevant data, work elements
Examine
Work element breakdown and effective method
Measure
Work in each element (time), VA and NVA
Define
Work Method (Why, What, Where, When, Who and How)
Compile
Work Allowances and determine standard time
Install
Std. work instruction training and visual instructions
Maintain
Workflow balance and standard work audit

5. Work Measurement Applications
The Work Flows of
• Material
• People
• Machine
• Information
• Service
• Layout
• Cash
• Environment
Value Stream/Process Flow Mapping
Capacity and Lead Time Analysis
Production Plan/Production Standards
Scheduling
Labor/Staffing Analysis/Labor Standards
Production Incentives
Machine Efficiencies (OEE)
Costing
Product Design
Layout Planning
Ergonomics
Inventory Planning/ERP
Information Systems
Simulation Modeling
Flow Manufacturing & Service
Learning Curves and Training
Productivity/Efficiency & Effectiveness

6. Work Measurement Techniques

7. 7 Workflows to look at 1-Does the Material flow ?
Move from one value adding processing step right to the next value adding step
2-Do the Operators flow ?
Is the operator’s work repeatable and consistent within each cycle ?
Can the operator perform efficiently from one value adding work element to the next ?
3-Do Machines/Equipment/Tools flow ?
Are the machines or equipment adding value to the product/service ?
4-Does Information flow ?
Is there a plan and schedule that maximizes flow?
Does everyone know the hourly production target ?
How quickly are problems and abnormalities noticed?
What happens when there are problems and abnormalities ?
5-Does the Service or Mgt Business Support Function flow ?
Are the service functions in the company flowing efficiently and supporting flow?
6-Does the Layout (facility) flow ?
Are the material, operators, equipment and information flowing efficiently?
7-Does the Cash flow ?
What is the material idle time (cash in-idle), WIP, TH, CT and inventory turn over? (Not applicable in this case)

8. Ergonomic/Human Factors
PFD Allowances
Personal
Fatigue
Delays
Arrangement and Storage of Tools
Lighting
Color
Noise & Vibration
Climate & Ventilation
Toxic Substances
PPE
Work Time and Rests
Facilities

9. The 5 Work Symbols and 7 Wastes
Any activity that consumes resources and creates value or non-value added for the customer
7 Wastes
Motion
Overproduction
Waiting
Transportation
Inventory
Unnecessary Processing
Defects
5 Work Symbols
Operation
Storage
Delay
Transport
Inspection VA
NVA

10. Initial template Process Flow Analysis Process Description:
Person Observed Observer
Date: Material People Machine Information
No.
Task Description
Cum. Time (min)
Interval Time (Min)
Distance (m)
Operation
Transport
Storage
Delay
Inspection 1
Get tube and place to bender 5 6 2
Get bent tube and place to assy 10 3
Get connector 15 4
Get hose & place 19
Start assembly cycle 24
Walk and bring finished piece 31 7
Attach to convolute 35 8 41 9
Place to tester fixture 16
Inspect part 52 11
Attach to coiler 57
Current
Total 20 32
Steps Count
Work Flow Cycle Efficiency
35%
Proposed
#####

11. Calculations
Takt time can be defined as the maximum time per unit allowed to produce a product in order to meet demand
Where: T   = Takt time, e.g. [minutes of work / unit produced] Ta = Net time available to work, e.g. [minutes of work / day] Td = Time demand (customer demand), e.g. [tons required / day]
*For SD, some for of output measurement will be defined. Any ideas? Each person being measured will have an output that is measured. Input can be considered as ‘time’

12. Achieving Standard Work
Routine for work to be performed right the first time, every time
Elements of Standard Work
1-Takt (Demand Rate)
2- Standard WIP (will be used if we use production as a measure)
3-Work sequence (Work Instruction, Documentation & Training)
(Work-in-Process = Cycle Time x Throughput)

13. Sustaining and Improving
Standardization Drives Sustainable Results

14. Let’s get started Look at schedules 1 person per day…for 3 weeks.
Take a template and fill in the tasks you have to complete per day (roughly)
Carry out your day as normal
Your work will be measured while you do it. Remember, this is not for bringing you down, but rather to assist you to carry your work out efficiently