IENG 451

Standardized Work

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

• Takt time • Work sequence • In-process stock

• Goal is to synchronous Takt time and cycle time

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

𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦=𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑜𝑛𝑡𝑖𝑚𝑒𝑝𝑒𝑟 h𝑠 𝑖𝑓𝑡

𝑝𝑟𝑜𝑐𝑒𝑠𝑠 𝑡𝑖𝑚𝑒+𝑠𝑒𝑡𝑢𝑝𝑡𝑖𝑚𝑒 / 𝑖𝑛𝑡𝑒𝑟𝑣𝑎𝑙No Name M/C

Man Time

Mach Time

TimeTo comp.

Inter changes Capacity

Time tochange

Basic Operation Time Tool Changes

3MIL 1764 Machine face

1 25 28 100 60 965

Standard Work Table

Standard Work Chart

Job Element Sheets

Line balancing

1 2 3 4 5 6 Station

time

1 2 3 4 5 6 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