1. UNCLASSIFIED / FOUO National GuardBlack Belt TrainingModule 43 Standardized WorkUNCLASSIFIED / FOUO

2. UNCLASSIFIED / FOUOCPI Roadmap Improve 8-STEP PROCESS6. See 1.Validate2. Identify 3. Set 4. Determine5. Develop7. Confirm8. Standardize Counter-the Performance Improvement Root Counter-ResultsSuccessful MeasuresProblem GapsTargets Cause Measures& ProcessProcesses ThroughDefineMeasureAnalyze ImproveControl TOOLSACTIVITIES 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 / FOUO2 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. UNCLASSIFIED / FOUO Exercise: Standardized WorkDraw A Pig Exercise UNCLASSIFIED / FOUO 4 5. UNCLASSIFIED / FOUO 5UNCLASSIFIED / FOUO 5 6. UNCLASSIFIED / FOUO Standard Operating ProcedureStatus Final Standardize Work InstructionRevision1 Rev. Date 8/29/2005 Procedure Number PIG0001-APage 1 of 1Task DescriptionSub- InstructionsTask1 Draw a letter M at the top left intersection. 1.1 Bottom center of M touches intersection2 Draw letter W at bottom left intersection 2.1 Top center of W touches intersection3 Draw letter W at bottom right intersection3.1 Top center of W touches intersection4 Draw arc from letter M to top right intersection5 Draw another arc from top right intersection tobottom right W6 Draw an arc between the two bottom Ws7 Draw the letter O in center left box8 Draw arc from letter M to tangent of the circle9 Draw arc from left W to tangent of the circle 10 Draw an arc for the mouth 10.1Half way between the W and circle10.2Must be a happy pig11Draw an arc for the eyes11.1Half way between the M and circle 12 Draw cursive letter e near top of arc on right 13Draw two dots in middle of circle for pigs nose. 6UNCLASSIFIED / FOUO 6 7. UNCLASSIFIED / FOUO What is Standardized Work? The standardized work is the detailed and timed description ofthe best possible succession of basic tasks for to complete ajob The standardized work main goal is the achievement of safety,quality, productivity and delivery performance objectivesStandardized Work is based on 3 forms: Standard Operation Sheet Standardized Work Chart Work Combination TableUNCLASSIFIED / FOUO 7 8. UNCLASSIFIED / FOUOStandard Operation SheetDefinition Key Elements:Establishing the best working The process detailssequence for a process, to ensurethe operators safety, the products The working sequence broken down intoquality as well as the processs elementsefficiency Key visuals to illustrate each steps The Best The classification of work Way Sign off from the team responsible for following the standardWho Should Use and why?The SW sheet is a tool to enable thework groups to take control of their ownKey Benefits:working practices. It supports theAssists trainingapplication of best practice, with allOne way of doing thingsrelevant parties sharing skills andknacks, and helps protect the customerBetter (consistent) qualityby improving the quality of the product.Safe working practiceIt also provides an invaluable training Helps to solve problemstool for new members. UNCLASSIFIED / FOUO 8 9. UNCLASSIFIED / FOUO Standard Operation SheetHow 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 operationConsider applying the 4 principles of Develop the best current method motion economy Confirmation stage Reduce motions Identify Main StepsPerform motions simultaneously Identify Key PointsReduce distances/effort Write the Standard Operation Make motion easier Can the operators follow the Standard Operation safely?UNCLASSIFIED / FOUO 9 10. UNCLASSIFIED / FOUO Standard Operation Sheet This form details all the Document No.: xxxx STANDARD OPERATIONFIS-F-PS-241 / EN version 01Plant:Washington Revision Level: 4 instructions to realize anPartWork- Page Numberxxx Part NameBolsterLine :EQ Bolster station: WoodstockNo: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.41 Remove parts from tool describing it by the safest, Place parts onto left side of bench (Fig1)SpikingRemove the spiking Cavitie easiest and most efficient Remove the waste then place the frame onto the bench2 frame from the upper Ensure frame handle is pointing away from you and spikes are pointing upwards. 1 4 s Cavities 321 2tool way. Fig 1. 3Fold waste and place Fold the waste from the frame and place it onto the granulator cooling stand, using it to3 onto to stand. push the existing waste into the granulator (fig 2). Contrary to the StandardizedGranulator Work Chart and WorkRemove the spikedRemove the spiked frame from underneath the bench place it into the guides on the upper mould tool (fig 1)Cooling stand4 frame from the Combination Table relative tounderneath bench Ensure that the handle is pointing towards you is fully located against the censor Fig 2. W hite 5 an operator, this document isPlace 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 location5 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 clW hite operation from the process. Fig 3.Issued Signature Checked Signature ApprovedSignatureSKILLEDSignatureNon Conforming Product:Name:Name: Name:OPERATOR P lace rejects in reject co ntainer. Reco rd o n P ro cess M o nito rFunction:Function: Function:Name: Sheet. If 3 o r mo re rejects fo und with same fault call Gap Leader. UNCLASSIFIED / FOUO 10 11. UNCLASSIFIED / FOUO Standard Operation Sheet Cycle Time DiagramDocument No.: xxxxSTANDARD OPERATIONFIS-F-PS-241 / ENversion 01 Plant: Washington Revision Level: 4 PartWork- PageTakt time Numberxxx Part Name BolsterLine : EQ Bolster station: WoodstockNo:1/1Time:No. Operation = SAFETY= QUALITY= TIP30 Sec Sketches / Photos / etc.4 1Remove 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 benchCavitie 2 frame from the upper 4 sCavities3211toolEnsure frame handle is pointing away from you and spikes are pointing upwards. 1Fig 1.23 Fold waste and place Fold the waste from the frame and place it onto the granulator cooling stand, using it to23push the existing Time onto to stand. waste into the granulator (fig 2).Granulator34 Remove the spiked frame from theRemove the spiked frame from underneath the bench place it into the guides on theupper mould tool (fig 1) Cooling stand underneath bench Ensure that the handle is pointing towards you is fully located against the censorFig 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&4on cavity 4.4 - Take one white & green RH clip from the dispencer.- Place the green clip into the center cl Gree n W hiteFig 3. Issued SignatureChecked SignatureApprovedSignature SKILLEDSignature Non Conforming Product: Name:Name: Name:OPERATOR5Function: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. 12 34StationsUNCLASSIFIED / FOUO 11 12. UNCLASSIFIED / FOUO Standardized Work ChartThis document describes theStandardized work chartFAU-F-PSE-006 /1succession of basic tasks andProduct: panel Process: welding, assembly Operation from:to:Date:the position of the operator for Takt Time Expected nb parts waitingeach of them.Machine 4 (Welding) Quality inspection61 s SafetyIt helps to visualize easily the Station 5 (Inspection) Cycle timeMovement w ith partoperator movements and tow ithout partidentify useless movements Production FP cart51 s 5 name:21(round trip,). 6 Expected 3 number of date: parts waiting7 10 48MethodsIt determines the number of name:93parts between each date:workstation.Quality name:This document is also used to date:train new operators.UNCLASSIFIED / FOUO12 13. UNCLASSIFIED / FOUOWork Combination Table It gathers all the basicSTANDARDIZED WORK COMBINATION TABLE tasks identified on the FAU-F-PSE-007 /1PRODUCTTAKT TIME: ProductionMethodsQualityWORKSTATION Standardized Work ChartREFERENCEVolume:ANALYZED BY:NUMBER: DATE:/// // /N TIMEOPERATION TIME and details each specific OPERATION NAMEMANU AUTO WALK510 15 20 25 3035 40 4550 5560 Pick waiting part1 2 time. 2 Position part2 3 CT = 51s3 Weld515 It helps differentiate times Functional inspection4 3 3 Welding inspection5 2 spent walking and waiting6 Surface inspection32TT = 61s from working on the7 Pick inspected part 28 Place part in cart4 3 workstation. 9 Pick welded part10 Position part for inspection33 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. UNCLASSIFIED / FOUOWork Combination TableWork sequence1,2,3,...Manual OperationsPlace Part .Manual work timeAutomatic machine timeWalk timeC.T. - Black LineCycle time / Takt timeT.T. - Red Line Wait timeUNCLASSIFIED / FOUO 14 15. UNCLASSIFIED / FOUO Standard Work 1. Standard2. Is a method of workWork5. Identify Problemsdefining how to do the jobStandardWorkSheetof making quality products4.ExecuteC.I.3. Pursue Root Continues Improvementsafely and cheaply. MeasuresCauses andPrepare C.I. (C.I.)MeasuresProduction Cell in Factory Standards are not supposed to be fixed and permanentStandards 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 / FOUO15 16. UNCLASSIFIED / FOUO Standard Work Enables continual improvementStandard 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 effectare only part of a processIt lives It changesIt improves It trains It must be used UNCLASSIFIED / FOUO 16 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/shiftsUNCLASSIFIED / FOUO 17 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. UNCLASSIFIED / FOUO Job Training MatrixTrainedIn TrainingTraining Planned this Year UNCLASSIFIED / FOUO 19 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 withLine is unbalanced.extra time available fromone operator.UNCLASSIFIED / FOUO 20 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 neededUNCLASSIFIED / FOUO 21 22. UNCLASSIFIED / FOUO Takeaways Standard Work is the documentation, communication,and storage of best practices for a particular processby personnel performing the work Standard Work uses Lean tools to develop and isessential to eliminate variation, defects, and chaos! Standard Work is essential for flow Leaders dont create standards for personnel but dohold people accountable to standardsUNCLASSIFIED / FOUO 22 23. UNCLASSIFIED / FOUOWhat other comments or questionsdo you have?UNCLASSIFIED / FOUO 23 24. UNCLASSIFIED / FOUOStandard Operating ProcedureStatus Final Standardize Work Instruction Revision2Rev. Date 8/29/2005Procedure Number PIG0001-APage 1 of 1 24UNCLASSIFIED / FOUO 24