Standardized Work: The Foundation for Kaizen (1 Day Class)
Standardized work is one of the most powerful but least used lean tools. By documenting the current best practice, standardized work forms the baseline for kaizen or continuous improvement. As the standard is improved, the new standard becomes the baseline for further improvements, and so on. Improving standardized work is a never-ending process.
Basically, standardized work consists of three elements:
- Takt time, which is the rate at which products must be made in a process to meet customer demand.
- The precise work sequence in which an operator performs tasks within takt time.
- The standard inventory, including units in machines, required to keep the process operating smoothly.
Establishing standardized work relies on collecting and recording data on a few forms. These forms are used by engineers and front-line supervisors to design the process and by operators to make improvements in their own jobs. In this workshop, you'll learn how to use these forms and why it will be difficult to make your lean implementations "stick" without standardized work.
This workshop assumes you are familiar with basic lean terms and concepts as described in Lean Thinking by Jim Womack and Dan Jones. A good article to read prior to attending is "Decoding the DNA of the Toyota Production System" (Harvard Business Review).
The benefits of standardized work include documentation of the current process for all shifts, reductions in variability, easier training of new operators, reductions in injuries and strain, and a baseline for improvement activities.
Standardizing the work adds discipline to the culture, an element that is frequently neglected but essential for lean to take root. Standardized work is also a learning tool that supports audits, promotes problem solving, and involves team members in developing poka-yokes.
This workshop is based on a "hear-see-do" format, so you'll learn the key concepts through instruction, discussion, simulation, and small-group exercise. You'll learn:
- Standardized work basic concepts and examples from various industries.
- The difference between work standardization and standardized work.
- The three elements of standardized work (takt time, work sequence, standard in-process inventory).
- The three documents for establishing standardized work (production capacity sheet, combination table, work chart).
- The three requirements for standardized work (work, equipment and line, quality)
- Standardization techniques: poka-yoke, visual management, SWIS, checking and auditing.
- How to choose the standardization techniques suitable for your environment so that you can effectively ensure your process is consistent and your results are predictable.
- The Toyota approach to kaizen.
- How to observe work before you standardize it.
At the end of this workshop, you will be able to:
- Understand the fundamentals of standardization and its importance in the foundation of a lean system.
- Prepare standardized work forms.
- Introduce standardization techniques to improve:
- Waste elimination
- Sustainability of improvements
- Predictability of results
Who Should Attend:
Those who would benefit from this workshop include:
- Operators (by understanding the importance of following standardized work rigorously and how they can make improvements through kaizen)
- Line supervisors (by learning how to observe people's cycle times, movements, and process steps)
- Engineers and lean leaders (by understanding how to introduce, support, and teach standardization)
- Managers (by understanding how to audit for adherence)
- Organizations at any stage in a lean transformation that are struggling with:
- Failures to sustain the results from past kaizen events
- Problems training new employees
- Inability to work within takt time or consistent cycle times
Standard Work Forms
- Standard Work Process Study Sheet »
- Standard Work Production Analysis Board »
- Standard Work Skills Training Matrix »
- Standardized Work Process Capacity Sheet »
- Standard Work Operator Balance Chart(OBC) »
- Standardized Work Chart »
- Standardized Work Combination Table »
- Standardized Work Job Instruction Sheet »
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