Standard Work

 

Having been working as a lean consultant for a couple of decades, I continue to be amazed at the number of times I walk through the door of an organization undertaking some "lean" improvement who cannot give the definition of standard work, and have never seen a standard work combination sheet, or a standard work layout sheet.

To refresh your memory, standard work is made up of three things; takt time, work sequence and standard work in process. Takt time is a theoretical calculation that shows the relationship between the time available to do the work and the volume of work to be done. You can see my earlier blog on takt time if you want more information on this topic. Here's the link.

Takt Time - Does this apply to my process? (breakthroughhorizonsltd.blogspot.com)

Work sequence is pretty easy to understand. What is the easiest, safest, lowest cost, highest quality sequence of tasks necessary to complete the work in a standardized way. Think of this as a recipe. Baking a cake from the recipe on the box, is an example of the work sequence.

Finally we need to consider the standard work in process. This is planned inventory between steps  to enable a process to flow to takt time. If we need to package chairs at a rate of 20 minutes per chair, and the glue from the previous step takes 60 minutes to dry, then we need 3 pieces of standard work in process (60 minutes drying time divided by 20 minutes of takt time)to enable one piece flow at packing.

The standard work is documented on the standard work combination sheet. This is a well aged form that shows the takt time, and the work sequence. The work sequence is documented with standard time associated for each task which is extremely valuable for training and auditing as well as for identifying further opportunities for cycle time reduction. Here is an example of the standard work combination sheet.



The standard work in process is documented on the standard work layout sheet. If you are a true lean champion, you should be familiar with and competent in both of these forms. When you can accurately complete these forms, train everyone to the new standard, and hold staff accountable to following the standard, you can then say you have "standard work".

Lean Blessings;

Ron

Ron Bercaw
President and Sensei
Breakthrough Horizons LTD
 www.breakthroughhorizons.com

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