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Standardized Work: The Foundation for Kaizen (1 Day Class)

Description:
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.

Suggested Reading:
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).

Benefits:
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.

Course Outline:
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.

Learning Objectives:
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:
    • Training
    • 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

Other Resources:

Standard Work Forms

Articles

Instructors:

Suggested Reading for this Workshop:
Locations and Dates for Standardized Work: The Foundation for Kaizen
March 7
Lean Enterprise Institute
Cambridge, MA
Instructor: Sammy Obara
Hotel Discount Available
Important Information About This Event & Location

We encourage you to make hotel accommodations early.


Price: $800.00 ($700.00 if the participant is taking 2 or more workshops at one location)
Price includes all participant materials, breakfast, lunch and snacks each day

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Our workshops are designed to cater to a limited number of participants.  If you must cancel a workshop registration, you will be given a full refund up to four weeks before the workshop.  A cancelation occuring within four weeks of the workshop will be subjected to a $350 cancelation fee, with the exception of the Herman Miller tours which with incur a cancelation fee of 50% of total paid.  LEI will not be held personally responsible for any incidental cost incurred (hotel, airfare, change fee, etc).  To cancel a workshop or tour registration, please call LEI at (617) 871-2900.