Production System Effiency

STANDARDIZED WORK

TRAINING

Definition – Standardized Work A timed description of the best possible succession of basic manual tasks for an operator.

It includes:

- transformation and control operations

- but also movements

- other necessary steps included in the cycle time.

Objective

Achievement of safety, quality, productivity and delivery performance objectives through:

• reduce dangerous movements

• apply controls and ability to repeat

• correct use of machines

• identification and elimination of the 7 wastes

• training and evaluation of the operators

Key Factors•Allows the repeatability of the sequence of basic tasks during each cycle with low variability of the process.

•Work content may differ according to product options

• Separate the man and machine

• Reduce frequencial operations (reduce variability)

• Quick and efficient treatment process of improvement ideas through the operator

Cycle Time and Takt Time

Takt time is a rate that represents, in seconds, the number of parts the customer expect us to deliver

Cycle time is a rate, in seconds, at which the product must be produced in order to offset “waste” in the system and achieve the Takt Time needed to satisfy the customer

Work ContentSum of the basic tasks carried out at each workstation to obtain a complete and good product (amount of work for a part)

It is measured by timing the cycle of each operator using a cycle time measurement form. The measurement must be based on 20 consecutive cycle times (everything included).

Time necessary for self-inspection has to be included.

For each operator, we will show the minimum time, wait time excluded, as well as the maximun and mean time.

FORMS

The standardized work goal is based on 3 forms:

• Standardized Work Chart ( FAU-F-PS-5006)

• Work Combination Table (FAU-F-PS-5007)

• Standard Operation Sheet (FAU-F-PS-0241)

Standardized Work Chart

- describes the succession of basic tasks and the position of the operator for each of them.

- helps to visualize easily the operator movements and to identify useless movements

- determines the number of parts between each workstation.

Standardized Work ChartOperation from: Date:

to:

Takt Time Expected nb parts waiting

61 s

Cycle time

51 s

Expected number of parts waiting

3

FAU-F-PS-5006 /1

Product: panel Process: welding, assembly

Standardized work chart

Machine 4 (Welding)

Station 5 (Inspection)

FP cart12

3

4

5

6

710

8

9

Sketch operator's workstations. Break his/her work down into elementary tasks corresponding to those in the standard work combinaison table.

Number the operator's position for each job

Add symbols

Part awaiting operator (e.g. At end of cycle)

Special hasard or safety action

Qualityinspection

Safety

Movement

w ith part

w ithout part

Productionname:

date:

Methodsname:

date:

Qualityname:

date:

Work Combination Chart

- gathers all the basic identified tasks on the Standardized Work Chart and details each specific time.

- helps differentiate times walking and waiting from working on the workstation.

- allows to evaluate the difference between cycle time and takt time and to verify that operators do not wait for the machine.

Work Combination Chart

/ / / / / /

SYMBOLS: - MANUAL: AUTO: WALK: IDLE:15

PRODUCT REFERENCE NUMBER:

WORKSTATION ANALYZED BY:

TAKT TIME: Quality

Volume:

DATE:

Production Methods

STANDARDIZED WORK COMBINATION TABLE

TIME OPERATION TIME

WALKAUTOMANUOPERATION NAME

N° 45 6015

2

3

15TOTAL

35

30

3

2

4Functional inspection

3

310Position part for inspection

3 Weld

Welding inspection

2

3

Pick waiting part

2Position part

1

5 15

Place part in cart

9 Pick welded part

2

7 Pick inspected part 2

Surface inspection

5

6

8

3

50

3

34

25

2

555 10 403020

CT = 51s

TT = 61s

Record time spent on:- manual operations - automatic operations- walking (1m = 1s)

Break work down into elementary tasks, numbered as in the standard work chart

Represent the times graphically, differentiating among:- manual time ( ______ )- automatic time (-----)- walking (~~~~)- idle time (====)

FAU-F-PS-5007 /1

Standard Operation Sheet

- details all the instructions to realize an operation at a workstation describing it by the safest, easiest and most efficient way.

- contrary to the standardized work chart and work combination table relative to an operator, this document is linked to a process or a basic operation from the process.

Standard Operation Sheet

STANDARD OPERATION FAU-F-PS-241 / ENversion 02

Part Number xxx Part Name Bolster

Name:

= SAFETY = QUALITY = TIP

Issued Signature/Date Checked Signature/Date

Name: Name:P lace rejects in reject container. Record on P rocess Monitor

Sheet. If 3 or more rejects found with same fault call Gap Leader.Function: Function: Function: Name:

Signature/Date SKILLED

OPERATOR

Non Conforming Product:Approved Signature/Date

5 Place one white & green clip into cavities 3&4

- 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 on cavity 4.- Take one white & green RH clip from the dispencer.- Place the green clip into the center cl

4Remove the spiked frame from the underneath bench

Remove the spiked frame from underneath the bench place it into the guides on the upper mould tool (fig 1)

Ensure that the handle is pointing towards you is fully located against the censor

3 Fold waste and place onto to stand.

Fold the waste from the frame and place it onto the granulator cooling stand, using it to push the existingwaste into the granulator (fig 2).

2Remove the spiking frame from the upper tool

Remove the waste then place the frame onto the bench

Ensure frame handle is pointing away from you and spikes are pointing upwards.

1 Remove parts from tool Remove cavities 3 & 4 from the mould tool.Place parts onto left side of bench (Fig1)

No. Operation 30 Sec Sketches / Photo's / etc.

Line : EQ Bolster Work-station: Woodstock

Plant: Washington

4

Granulator

1

Safety issue: to be used if a real risk exists for employees !

Important remarks can be written in bold or underlined

Operator who participated in setting up the Standard Operation

Non-ComformanciesReaction rules have to be adapted to the workstation

Tip : put the stress on special comments

Whole Time needed according to the Standardized Combination Table

big fontenables operator to read from worstation

"Alt+Enter"to go on the next line in the same cell

Self-Quality check

Time:

Standard Operation Sheet

Fig 1.

Fig 2.

Fig 3.

STANDARD OPERATION FAU-F-PS-241 / ENversion 02

Function:

5 Place one white & green clip into cavities 3&4

- 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 on cavity 4.- Take one white & green RH clip from the dispencer.- Place the green clip into the center cl

Signature/Date

2Remove the spiking frame from the upper tool

4Remove the spiked frame from the underneath bench

3 Fold waste and place onto to stand.

Remove the waste then place the frame onto the bench

Ensure frame handle is pointing away from you and spikes are pointing upwards.

Fold the waste from the frame and place it onto the granulator cooling stand, using it to push the existingwaste into the granulator (fig 2).

Remove cavities 3 & 4 from the mould tool.Place parts onto left side of bench (Fig1)

Sketches / Photo's / etc. = SAFETY = QUALITY = TIP

Signature/Date Signature/Date

xxxx

4

1/1

Document No.:

Rev ision Level:

Woodstock

Washington

Work-station:

Plant:

P lace rejects in reject container. Record on P rocess Monitor Sheet. If 3 or more rejects found with same fault call Gap Leader.

Name: Name:

Non Conforming Product:

Function:

Signature/DateIssued Checked

Name:Function:

1

30 Sec

Remove parts from tool

Operation No.

Remove the spiked frame from underneath the bench place it into the guides on the upper mould tool (fig 1)

Ensure that the handle is pointing towards you is fully located against the censor

SKILLED

OPERATOR

Approved

Name:

xxx Page No:

Part Number

Part Name Line :Bolster EQ Bolster

Cavities

Spiking

Cavities 234 1

Granulator

Cooling stand

White

GreenWhite

1 2

3

4

5

Time: