|
|
|
08/09/2012 12:21 PM
|
|
|
I would be interested to hear people's thought on this:
We have a chemical process that produces different parts. Each part has different steps it goes through to be processed (unique chemicals, different pieces of equipment, run times, speeds, etc.) For each unique part there is a "batch sheet" that describes what needs to be done at each step, quality parameters for each step, and how long some of the steps should take. After each step is completed the operator initials that it has been done. Later, the supervisor reviews the batch sheets.
1) From a Lean perspective would these batch sheets be considered a form of Standard Work?
2) What applications of Standard Work would benefit this process?
3) Other thoughts, ideas, or examples of applications of Standard Work in a Chemicals and a Refiner operations?
|
|
|
|
|
08/10/2012 09:00 AM
|
|
|
Hi Steve,
I work in the specialty chemical field and we consider the batch sheet a standard work document. The operator must follow the process as written and like yours he must initial each step. We have tried to implement other forms of standard work like tank washing for example with success. We use the 5s process to manage our production and packaging carts that contain the tools required for each. We have struggled along the way tying to utilize kanban because we have a multitude of products and raw materials which are in many container varieties. Good luck with your journey.
|
|
|
|
|
08/10/2012 09:00 AM
|
|
|
Steve,
Not sure of your application. IF the steps are done by different people, then no. Standard work is individual operator based, mapping the same routine used in repetitive cycles. Your batch sheet here is more of a 'traveler', verifying the steps.
IF the individual associate does the same thing all the way through, yes, the batch sheet is a form of standard work - but having the associate initial each step is a show of mistrust.
Breaking it down further (into actual job training), each step - transfer, rinse, test - would be done the same way with the same checks and balances (safety equipment, ventilation). This would need to be reviewed
By the way, why does the supervisor review the batch sheets? To see if people can sign their names? to assess a process, you have to watch the actual thing.
|
|
|
|
|
08/10/2012 10:24 AM
|
|
|
I agree with Dan regarding the initialing of the batch sheets. This does show mistrust.
And, having the supervisor review the batch sheets is muda. There is no value added to the process by doing this.
|
|
|
|
|
08/13/2012 09:38 AM
|
|
|
In our case the initial is to identify who did the step within the process. 90% of the time it is the same person but on occasion cross trained operators are needed elsewhere requiring that someone else complete the batch. Verification does not necessarily translate to mistrust in my opinion, but I get your point.
|
|
|
|
|
08/20/2012 04:57 PM
|
|
|
Mistrust or not, it still does not add value.
If you strive for Standard Work that is mistake proof, you remove this unnecessary step,
|
|
|
|
|
08/22/2012 11:21 AM
|
|
|
This is an interesting topic. Just yesterday we had a debate over the signing off of documents, it was asked why the teamleader had to countersign something a operator signed off.
This is especially flawed when the teamleader does not understand the process they are signing off and often simply sign because they have to. They may even not notice inconsistancies and errors in the log sheet.
As we have more and more signoffs for the operators (prestart checks, and cleaning checks) I'm leaning toward putting the responisibility back on the operators. They take their Prestart/cleaning book from the wall in the morning and return it at night. The team leader then just has to look to see if any books are missing from the matrix. A very quick visual check.
We could even have it so the books get flipped last thing at night over to show a red band and as the books are returned they get place the right way up, showing a green band. Once again a easy visual check that the book has been taken and used.
|
|
|
|
|
08/30/2012 01:06 PM
|
|
|
Have you checked "Lean in the Process Industries" by Peter L.King?
|
|
|
|
>
Community >
Forums
Send to a Friend
