NG BB 43 Standardized Work

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NG BB 43 Standardized Work

  1. 1. UNCLASSIFIED / FOUO National Guard Black Belt Training Module 43 Standardized Work UNCLASSIFIED / FOUO
  2. 2. UNCLASSIFIED / FOUOCPI Roadmap – Improve 8-STEP PROCESS 6. See 1.Validate 2. Identify 3. Set 4. Determine 5. Develop 7. Confirm 8. Standardize Counter- the Performance Improvement Root Counter- Results Successful Measures Problem Gaps Targets Cause Measures & Process Processes Through Define Measure Analyze Improve Control TOOLS ACTIVITIES •Brainstorming • Develop Potential Solutions •Replenishment Pull/Kanban • Develop Evaluation Criteria •Stocking Strategy • Select Best Solutions •Process Flow Improvement • Develop Future State Process Map(s) •Process Balancing • Develop Pilot Plan •Standard Work • Pilot Solution •Quick Change Over • Develop Full Scale Action/ •Design of Experiments (DOE) Implementation Plan •Solution Selection Matrix • Complete Improve Gate •‘To-Be’ Process Mapping •Poka-Yoke •6S Visual Mgt •RIE Note: Activities and tools vary by project. Lists provided here are not necessarily all-inclusive. UNCLASSIFIED / FOUO 2
  3. 3. UNCLASSIFIED / FOUO Learning Objective  Use Lean techniques to improve the process  Understand and apply Standardized Work techniques and process control tools UNCLASSIFIED / FOUO 3
  4. 4. UNCLASSIFIED / FOUO Exercise: Standardized Work Draw A Pig Exercise UNCLASSIFIED / FOUO 4
  5. 5. UNCLASSIFIED / FOUO 5 UNCLASSIFIED / FOUO 5
  6. 6. UNCLASSIFIED / FOUO Standard Operating Procedure Status Final Standardize Work Instruction Revision 1 Rev. Date 8/29/2005 Procedure Number PIG0001-A Page 1 of 1 Task Description Sub- Instructions Task 1 Draw a letter M at the top left intersection. 1.1 Bottom center of M touches intersection 2 Draw letter W at bottom left intersection 2.1 Top center of W touches intersection 3 Draw letter W at bottom right intersection 3.1 Top center of W touches intersection 4 Draw arc from letter M to top right intersection 5 Draw another arc from top right intersection to bottom right W 6 Draw an arc between the two bottom Ws 7 Draw the letter O in center left box 8 Draw arc from letter M to tangent of the circle 9 Draw arc from left W to tangent of the circle 10 Draw an arc for the mouth 10.1 Half way between the W and circle 10.2 Must be a happy pig 11 Draw an arc for the eyes 11.1 Half way between the M and circle 12 Draw cursive letter e near top of arc on right 13 Draw two dots in middle of circle for pigs’ nose. 6 UNCLASSIFIED / FOUO 6
  7. 7. UNCLASSIFIED / FOUO What is Standardized Work?  The standardized work is the detailed and timed description of the best possible succession of basic tasks for to complete a job  The standardized work main goal is the achievement of safety, quality, productivity and delivery performance objectives Standardized Work is based on 3 forms:  Standard Operation Sheet  Standardized Work Chart  Work Combination Table UNCLASSIFIED / FOUO 7
  8. 8. UNCLASSIFIED / FOUOStandard Operation Sheet Definition Key Elements: “Establishing the best working • The process details sequence for a process, to ensure the operators’ safety, the products • The working sequence broken down into quality as well as the process’s elements efficiency” • Key visuals to illustrate each steps The Best • The classification of work Way • Sign off from the team responsible for following the standard Who Should Use and why? The SW sheet is a tool to enable the work groups to take control of their own Key Benefits: working practices. It supports the Assists training application of best practice, with all One way of doing things relevant parties sharing skills and knacks, and helps protect the customer Better (consistent) quality by improving the quality of the product. Safe working practice It also provides an invaluable training Helps to solve problems tool for new members. UNCLASSIFIED / FOUO 8
  9. 9. UNCLASSIFIED / FOUO Standard Operation Sheet How do we develop Std Op. ? Develop the best method  Select Operation  Question what we are doing & when  Record data of Operation  If there are differences between areas which one gives us more benefits?  Analyze the operation Consider applying the 4 principles of  Develop the best current method motion economy  Confirmation stage Reduce motions  Identify Main Steps Perform motions simultaneously  Identify Key Points Reduce distances/effort  Write the Standard Operation Make motion easier  Can the operators follow the Standard Operation safely? UNCLASSIFIED / FOUO 9
  10. 10. UNCLASSIFIED / FOUO Standard Operation Sheet This form details all the Document No.: xxxx STANDARD OPERATION FIS-F-PS-241 / EN version 01 Plant: Washington Revision Level: 4 instructions to realize an Part Work- Page Number xxx Part Name Bolster Line : EQ Bolster station: Woodstock No: 1/1 Time: No. Operation = SAFETY = QUALITY = TIP Sketches / Photos / etc. operation at a workstation 30 Sec Remove cavities 3 & 4 from the mould tool. 4 1 Remove parts from tool describing it by the safest, Place parts onto left side of bench (Fig1) Spiking Remove the spiking Cavitie easiest and most efficient Remove the waste then place the frame onto the bench 2 frame from the upper Ensure frame handle is pointing away from you and spikes are pointing upwards. 1 4 s Cavities 3 2 1 2 tool way. Fig 1. 3 Fold waste and place Fold the waste from the frame and place it onto the granulator cooling stand, using it to 3 onto to stand. push the existing waste into the granulator (fig 2). Contrary to the Standardized Granulator Work Chart and Work Remove the spiked Remove the spiked frame from underneath the bench place it into the guides on the upper mould tool (fig 1) Cooling stand 4 frame from the Combination Table relative to underneath bench Ensure that the handle is pointing towards you is fully located against the censor Fig 2. W hite 5 an operator, this document is Place one white & green - Take one white & green LH clip from the dispenser. - Place the green clip into the center clip position and the white into the bottom location 5 linked to a process or a basic on cavity 4. clip into cavities 3&4 - Take one white & green RH clip from the dispencer. Gree n - Place the green clip into the center cl W hite operation from the process. Fig 3. Issued Signature Checked Signature Approved Signature SKILLED Signature Non Conforming Product: Name: Name: Name: OPERATOR P lace rejects in reject co ntainer. Reco rd o n P ro cess M o nito r Function: Function: Function: Name: Sheet. If 3 o r mo re rejects fo und with same fault call Gap Leader. UNCLASSIFIED / FOUO 10
  11. 11. UNCLASSIFIED / FOUO Standard Operation Sheet Cycle Time Diagram Document No.: xxxx STANDARD OPERATION FIS-F-PS-241 / EN version 01 Plant: Washington Revision Level: 4 Part Work- Page Takt time Number xxx Part Name Bolster Line : EQ Bolster station: Woodstock No: 1/1 Time: No. Operation = SAFETY = QUALITY = TIP 30 Sec Sketches / Photos / etc. 4 1 Remove cavities 3 & 4 from the mould tool. Remove parts from tool Place parts onto left side of bench (Fig1) Spiking Remove the spiking Remove the waste then place the frame onto the bench Cavitie 2 frame from the upper 4 s Cavities 3 2 1 1 tool Ensure frame handle is pointing away from you and spikes are pointing upwards. 1 Fig 1. 2 3 Fold waste and place Fold the waste from the frame and place it onto the granulator cooling stand, using it to 2 3 push the existing Time onto to stand. waste into the granulator (fig 2). Granulator 3 4 Remove the spiked frame from the Remove the spiked frame from underneath the bench place it into the guides on the upper mould tool (fig 1) Cooling stand underneath bench Ensure that the handle is pointing towards you is fully located against the censor Fig 2. W hite 5 - Take one white & green LH clip from the dispenser. Place one white & green - Place the green clip into the center clip position and the white into the bottom location 5 clip into cavities 3&4 on cavity 4. 4 - Take one white & green RH clip from the dispencer. - Place the green clip into the center cl Gree n W hite Fig 3. Issued Signature Checked Signature Approved Signature SKILLED Signature Non Conforming Product: Name: Name: Name: OPERATOR 5 Function: Function: Function: Name: P lace rejects in reject co ntainer. Reco rd o n P ro cess M o nito r Sheet. If 3 o r mo re rejects fo und with same fault call Gap Leader. 1 2 3 4 Stations UNCLASSIFIED / FOUO 11
  12. 12. UNCLASSIFIED / FOUO Standardized Work Chart This document describes the Standardized work chart FAU-F-PSE-006 /1 succession of basic tasks and Product: panel Process: welding, assembly Operation from: to: Date: the position of the operator for Takt Time Expected nb parts waiting each of them. Machine 4 (Welding) Quality inspection 61 s Safety It helps to visualize easily the Station 5 (Inspection) Cycle time Movement w ith part operator movements and to w ithout part identify useless movements Production FP cart 51 s 5 name: 2 1 (round trip,…). 6 Expected 3 number of date: parts waiting 7 10 4 8 Methods It determines the number of name: 9 3 parts between each date: workstation. Quality name: This document is also used to date: train new operators. UNCLASSIFIED / FOUO 12
  13. 13. UNCLASSIFIED / FOUOWork Combination Table It gathers all the basic STANDARDIZED WORK COMBINATION TABLE tasks identified on the FAU-F-PSE-007 /1 PRODUCT TAKT TIME: Production Methods Quality WORKSTATION Standardized Work Chart REFERENCE Volume: ANALYZED BY: NUMBER: DATE: / / / / / / N TIME OPERATION TIME and details each specific OPERATION NAME ° MANU AUTO WALK 5 10 15 20 25 30 35 40 45 50 55 60 Pick waiting part 1 2 time. 2 Position part 2 3 CT = 51s 3 Weld 5 15 It helps differentiate times Functional inspection 4 3 3 Welding inspection 5 2 spent walking and waiting 6 Surface inspection 3 2 TT = 61s from working on the 7 Pick inspected part 2 8 Place part in cart 4 3 workstation. 9 Pick welded part 10 Position part for inspection 3 3 2 3 It allows to evaluate the difference between cycle time and takt time and to verify that operators do not wait for the machine. UNCLASSIFIED / FOUO 13
  14. 14. UNCLASSIFIED / FOUOWork Combination Table Work sequence 1,2,3,... Manual Operations Place Part …. Manual work time Automatic machine time Walk time C.T. - Black Line Cycle time / Takt time T.T. - Red Line Wait time UNCLASSIFIED / FOUO 14
  15. 15. UNCLASSIFIED / FOUO Standard Work 1. Standard 2.  Is a “method of work” Work 5. Identify Problems defining how to do the job Standard Work Sheet of making quality products 4.Execute C.I. 3. Pursue Root Continues Improvement safely and cheaply. Measures Causes and Prepare C.I. (C.I.) Measures Production Cell in Factory  Standards are not supposed to be fixed and permanent  Standards should be changed every time continual improvement is made and depending on the skill level of operators.  They should also be subject to change whenever production volume is changed. UNCLASSIFIED / FOUO 15
  16. 16. UNCLASSIFIED / FOUO Standard Work  Enables continual improvement  Standard work is the starting point of continual improvement.  Elimination of all kinds of waste  Assigns the work to operators  Value is added at each stage  Line balances are maintained  Standards currently in effect are only part of a process It lives It changes It improves It trains It must be used UNCLASSIFIED / FOUO 16
  17. 17. UNCLASSIFIED / FOUOBenefits of Standard Work  Foundation or baseline for improvement  Improve safety  Avoid unnecessary motion and wasted effort  Increase quality of output  Prevents equipment damage  Reduces cost  Provides workers a means to define their jobs  Maintains consistency between workers/shifts UNCLASSIFIED / FOUO 17
  18. 18. UNCLASSIFIED / FOUO Operator Cross-Training  Cross-training is key to a lean workplace  As you are developing a standard operations routine evaluate whether all operators can do all jobs required  Develop a cross training plan with the team to close any gaps that exist UNCLASSIFIED / FOUO 18
  19. 19. UNCLASSIFIED / FOUO Job Training Matrix Trained In Training Training Planned this Year UNCLASSIFIED / FOUO 19
  20. 20. UNCLASSIFIED / FOUO Balancing Standard Work  Time to complete standard routines should be balanced between operators in a cell. A histogram can be helpful in accomplishing this as shown below. Note that the total time is the same for both lines. Line is balanced with Line is unbalanced. extra time available from one operator. UNCLASSIFIED / FOUO 20
  21. 21. UNCLASSIFIED / FOUO Standard Work Implementation Steps Development of standard operations 1. Calculate Takt time 2. Operators perform time studies 3. Team conducts line balance 4. Establish standard operation routines 5. Establish production capacity sheet 6. Establish standard in-process stock 7. Establish standard operations sheets 8. Identify waste (continuous improvement) 9. Revise 1 through 8 as needed UNCLASSIFIED / FOUO 21
  22. 22. UNCLASSIFIED / FOUO Takeaways  Standard Work is the documentation, communication, and storage of best practices for a particular process by personnel performing the work  Standard Work uses Lean tools to develop and is essential to eliminate variation, defects, and chaos!  Standard Work is essential for flow  Leaders don’t create standards for personnel but do hold people accountable to standards UNCLASSIFIED / FOUO 22
  23. 23. UNCLASSIFIED / FOUO What other comments or questions do you have? UNCLASSIFIED / FOUO 23
  24. 24. UNCLASSIFIED / FOUO Standard Operating Procedure Status Final Standardize Work Instruction Revision 2 Rev. Date 8/29/2005 Procedure Number PIG0001-A Page 1 of 1 24 UNCLASSIFIED / FOUO 24

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