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National Guard
Black Belt Training
Module 43
Standardized Work
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CPI 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

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Learning Objective
 Use Lean techniques to improve the process
 Understand and apply Standardized Work techniques
and process control tools
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Exercise: Standardized Work
Draw A Pig Exercise
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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
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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
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Standard 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.
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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?
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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 / Photo's / 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.
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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 / Photo's / 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
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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.
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Work 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.
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Work 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
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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.
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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
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Benefits 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
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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
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Job Training Matrix
Trained
In Training
Training Planned this Year
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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.
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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
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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
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What other comments or questions
do you have?
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Standard Operating Procedure Status Final
Standardize Work Instruction Revision 2
Rev. Date 8/29/2005
Procedure Number PIG0001-A Page 1 of 1
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