1

STANDARD WORK
2
TRAINING OBJECTIVES
Understand basics of Standard Work
Understand tools of Standard Work
Provide structured, consistent approach
to eliminate waste
Prepare for cell implementation, training
of associates & Value Stream Mapping
3

STANDARD WORK
Standard Work is a tool that defines
the interaction of a person and the
work area while performing work.

Standard Work details the motion of
the operator during the work process.
4
BASICS OF
STANDARD WORK
5
8 Types of Waste
Over Production
Waiting
Motion
Inventory
Transportation
Rework
Processing

Customers
Availability? Yield? Waiting?
Inventories? Re-work?
and people mis-utilization
6
3 DESIGN PRINCIPLES
Standard Work is a set of tools
to implement these principles.
1. TAKT - Rate of production required to
meet customer demand
2. FLOW - Smooth product flow with
minimum in-process inventory
Goal is 1 piece flow
Make flow visual
3. PULL - Produce what is needed, when it
is needed, in the amount it is needed

7
PULL
Suppliers
KCA
(Kit Consolidation Area)
1
2
3
PKA
(Part Kitting Area)
Suppliers
TEST
MODEL
B
MODEL
A
MODEL
A
TAKT TAKT
TAKT
FLOW
3 DESIGN PRINCIPLES
8
ELEMENTS OF WORK
Manual
^ Operator/mechanic hands-on activity
Automatic
^ Machine/equipment cycle
Walking
Delay
^ Holding or waiting to perform next
sequence
9
BENEFITS OF
STANDARD WORK
Documents the actual process
Targets areas above Takt Time
Tool for continuous improvement
Reduce inventory
Reduce lead time
Increase productivity
Standardize the work process
Increase capacity without increasing
resources
10
Takt Time
Work
Sequence
Standard
Work-In-Process
Components of
Standard Work
AFSxxxxx
Op10
Op20
Op30
11
TAKT TIME
Takt time is the time in which a unit
must be produced in order to match
the rate of customer demand.

Takt Time determines rate of production
Takt Time is subject to change every month
Total daily working time
Total daily customer demand
Takt Time =
11
12
AVAILABLE TIME EXAMPLE
Weekly 6S/TPM shutdown 120 24

Weekly QCPC meeting 60 12

Daily cleanup 75 15

Daily tool box meeting 25 5
Weekly
Time
Daily
Time
TOTAL 280 56 Min.
Available time for 2 crews = 2 x (480 - 56) = 848 min per day
13
TAKT TIME EXAMPLE
Average Daily Schedule = 100 units
# Working Minutes = 848
= 8.48 min/unit
Time available
Customer Demand
=
848 Min.
100 units
Takt Time =
Or
T/T = 8 minutes, 29 seconds
14
TAKT TIME, CYCLE TIME &
LEAD TIME
Takt Time = Rate of production to meet customer
demand
Cycle Time = Manual + walking + waiting time for
the operator to complete one cycle of work
sequence
Lead Time = Total time required for one unit to
complete entire process
= Total time for all operations + total
time in all inventories
15
WORK SEQUENCE
The order in which an operator performs manual operations
including walking and waiting.
Incoming
1
2
4
3
3
1
2
1
3
2
Operator A
Operator C
Operator B
Work sequence
1
2
3
4
5
6
7
8
9
10
Process Sequence
Outgoing
14
16
STANDARD WORK-IN-PROCESS
The minimum inventory required at each
workstation to support continuous flow and
meet customer demand (Takt).
Incoming
Outgoing
1
2
3
4
5
6
7
8
9
10
1 pc =
SWIP = 8
15
17
STANDARD WORK-IN-PROCESS
One-Piece Flow
Each work station or machine has
one piece (upstream and downstream
operations must be consideredcompare cycle times to Takt)
Minimum number of pieces
required for batch loads
(multiply by 2 to facilitate flow - see next page)
Auto time + unload/load time
Takt Time
Batch
Min. Batch Size =
18
BATCH OPERATIONS
Furnace
Auto Cycle = 480 Min.
(I ncludes load/unload)
T/T = 4 Min/pc
Auto time + load/unload time
Takt Time
480 Min.
4 Min/pc
(120 pieces)
Curtain
240 = Number of
SWIP for this furnace
Pull from this supply one
piece at a time for
return to one piece flow
Supply this side one
piece at a time
Batch Size =
= =
120 pcs
19
TOOLS OF STANDARD WORK
20
Standard
Work Tools
Time Observation
Chart
Standard
Work Sheet
Percent
Loading Chart
Standard Work Sheet
Scope of From Date prepared
Operations To or revised:
Quality Safety Standard Work- # of Pieces of Std. TAKT Cycle Operator
Check Precaution in-Process Work-in-Process Time Time Number


ELEMENT NO. ELEMENT TASK 1 2 3 4 5 TASK TIME NOTES ( M - W - A TIME)
USE BACK OF THIS PAGE
TO SKETCH WORKPLACE
P&W FORM 7837A REVISED 3/97
TIME OBSERVATION SHEET PAGE OF
PART NUMBER OPERATION NUMBER REV. LETTER SUM. LETTER
OPERATOR
PART NAME

DEPARTMENT NUMBER / NAME PREPARED BY
PCS / LOAD
OPERATION DESCRIPTION
DATE
BRASS TAG
MACHINE DESCRIPTION TIME

TOTAL
Process
Capacity Sheet
2
MACHINE CAPACITY BY PROCESS PAGE _____ OF ____
NEW / REVISED DATE
PART NUMBER DEPARTMENT NUMBER / NAME
PART NAME CURRENT DAILY OUTPUT AVAILABLE TIME MAXIMUM OUTPUT PER DAY

A B C D E F G H I J K
MACHINE PCS. / WALK MANUAL MANUAL AUTO TOTAL TIME/ PC TIMETO # PCS. TO TIME/ PC TOT / PC CALC. / REMARKS PROCESSCAPACITY
TASK # DESCRIPTION OF TASK NUMBER LOAD TIME INT EXT TIME (D + E) (F / A) CHANGE CHANGE (H / I ) (G+ J) (AVAI L. TI ME / K)











TOTAL NOTE: REVISE TIMES WHEN SIGNIFICANT IMPROVEMENTS ARE
INCORPORATED. DOCUMENT THE REASON IN THE
GRAND TOTAL "REMARKS" COLUMN.
Percent Load Chart
Operators
0
10
20
30
40
50
60
70
80
90
A B C D E
Operators
S
e
c
o
n
d
s
Walk
Manual External
Manual Internal
Walk
Manual External
Manual Internal
T/T
2 Shift
1 6
4
3
32
Operation
10
Operation
20
Operation
30
Operation
40
Auto
Manual
Walk
Wait
2 shift T/T = 37 sec
Time,
sec
50
38
38
30
STANDARD WORK COMBINATION SHEET (SWCS)
PART NUMBER OPERATION NUMBER REV. LETTER SUM. LETTER DATE TAKT TIME MANUAL
AUTOMATIC
WALK VVVVVVVVV
PART NAME DEPARTMENT NUMBER / NAME PREPARED BY WAIT
MAN.MACH.
STEP DESCRIPTION OF PCS / MAN
NO. TASK LOAD MACH MAN AUTO
TOTAL
TIME PER PIECE USE MINUTES PER PIECE FOR STANDARD WORK DATABASE
P&W F-7837 Revised 3/97
TASK TIME: 1 LINE = MINUTES SECONDS




WALK






Standard Work
Combination Sheet
5
Operations
Bar Chart
21
Old time observations
Guesstimates
Simulations

Time Observation
Establish Standard Work by observation
Multiple measures are recommended
2nd shortest observed time should be used



ELEMENT NO. ELEMENT TASK 1 2 3 4 5 TASK TIME NOTES ( M - W - A TIME)
USE BACK OF THIS PAGE
TO SKETCH WORKPLACE

P&W FORM 7837A REVISED 3/97
TIME OBSERVATION SHEET PAGE OF
PART NUMBER OPERATION NUMBER REV. LETTER SUM. LETTER
OPERATOR
PART NAME

DEPARTMENT NUMBER / NAME PREPARED BY
PCS / LOAD
OPERATION DESCRIPTION
DATE
BRASS TAG
MACHINE DESCRIPTION TIME

TOTAL
Std. Work begins with
time observation
22























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23

E L E M E N T
N O . E L E M E N T T A S K 1 2 3 4 5
T A S K T I M E
N O T E S ( M - W - A T I M E )
U S E B A C K O F T H I S P A G E
T O S K E T C H W O R K P L A C E
P & W F O R M 7 8 3 7 A R E V I S E D 3 / 9 7
T I M E O B S E R V A T I O N S H E E T P A G E O F
P A R T N U M B E R
O P E R A T I O N N U M B E R R E V . L E T T E R S U M . L E T T E R
O P E R A T O R
P A R T N A M E
D E P A R T M E N T N U M B E R / N A M E P R E P A R E D B Y
P C S / L O A D O P E R A T I O N D E S C R I P T I O N D A T E
B R A S S T A G M A C H I N E D E S C R I P T I O N T I M E
T O T A L
1. Fill in all
information
2. Observe operator
& record tasks
3. Record elapsed time
in upper square
-start at zero
4. Record task times
in lower square
5. Data accuracy increased through
multiple time observation
6. Use 2nd lowest
time for task
7. Record
Auto Times
Non repeatable Tasks
Observations
Opportunities for waste
reduction
8. Compute total times
0 0 0 0 0
24
2 Team Members per Observations:
1. Take 2 to 3 cycles to define the tasks. Make sure
you watch the same operator.
2. Once the tasks are well defined review with the
operator.
3. One person reads the watch the other observes
the tasks and calls out time when the task is
complete. Then he/she writes in the time on the
form
25
TIPS FOR TIME OBSERVATION
Fully understand and record work sequence
prior to timing
Keep watch running continuously
Stop the watch if operator work is
interrupted
Record time for tooling changes
Stop watch time observation is faster; video
is more accurate
Time observation should be conducted with
a proficient operator
26
Production Capacity
by Process
Part Process for
all parts in the cell

Operator time
(manual, walk, wait)
Machine time
*Automatic (untended)
*Tooling change & dressing cycles
Separates Manual
Work From
Automatic Work
1 2 3
6 5 4
27
MACHINE CAPACITY BY PROCESS PAGE _____ OF ____
NEW / REVISED DATE
PART NUMBER DEPARTMENT NUMBER / NAME
PART NAME REQUIRED DAILY OUTPUT AVAILABLE TIME MAXIMUM OUTPUT PER DAY

A B C D E F G H I J K
MACHINE PCS. / WALK MANUAL MANUAL AUTO TOTAL TIME / PC TIME TO # PCS. TO TIME / PC TOT / PC CALC. / REMARKS PROCESS CAPACITY
TASK # DESCRIPTION OF TASK NUMBER LOAD TIME INT EXT TIME (D + E) (F / A) CHANGE CHANGE (H / I) (G + J) (AVAIL. TIME / K)











TOTAL NOTE: REVISE TIMES WHEN SIGNIFICANT IMPROVEMENTS ARE
INCORPORATED. DOCUMENT THE REASON IN THE
GRAND TOTAL "REMARKS" COLUMN.
28
MACHINE CAPACITY BY PROCESS PAGE _____ OF ____
NEW / REVISED DATE
PART NUMBER DEPARTMENT NUMBER / NAME
PART NAME REQUIRED DAILY OUTPUT AVAILABLE TIME MAXIMUM OUTPUT PER DAY

A B C D E F G H I J K
MACHINE PCS. / WALK MANUAL MANUAL AUTO TOTAL TIME / PC TIME TO # PCS. TO TIME / PC TOT / PC CALC. / REMARKS PROCESS CAPACITY
# Process Descritption NUMBER LOAD TIME INT EXT TIME (D + E) (F / A) CHANGE CHANGE (H / I) (G + J) (AVAIL. TIME / K)











TOTAL NOTE: REVISE TIMES WHEN SIGNIFICANT IMPROVEMENTS ARE
INCORPORATED. DOCUMENT THE REASON IN THE
GRAND TOTAL "REMARKS" COLUMN.
Record all information 1. Record all information
2. Record operations 3. Record operation times
Manual int = machine running
Manual ext = machine stopped
Auto time
4. Record tool changes
times
frequency


5. Compute
F - Total auto + ext. manual time
G - Total time per piece
J - Time per piece for tooling change
K - Total time per pc including tooling
tooling changes
6. Compute process capacity
Process capacity = Available
time per day / total time per pc
29
INTERNAL vs EXTERNAL


Manual Internal

Operator performs manual work
while machine is running.


Manual External

Operator performs manual work
while machine is stopped.
30
MACHINE CAPACITY BY PROCESS PAGE _____ OF ____
NEW / REVISED DATE 2/18/98
PART NUMBER DEPARTMENT NUMBER / NAME
PART NAME REQUIRED DAILY OUTPUT AVAILABLE TIME MAXIMUM OUTPUT PER DAY
840 Min.
A B C D E F G H I J K
MACHINE PCS. / WALK MANUAL MANUAL AUTO TOTAL TIME / PC TIME TO # PCS. TO TIME / PC TOT / PC CALC. / REMARKS PROCESS CAPACITY
TASK # DESCRIPTION OF TASK NUMBER LOAD TIME INT EXT TIME (D + E) (F / A) CHANGE CHANGE (H / I) (G + J) (AVAIL. TIME / K)











TOTAL NOTE: REVISE TIMES WHEN SIGNIFICANT IMPROVEMENTS ARE
INCORPORATED. DOCUMENT THE REASON IN THE
GRAND TOTAL "REMARKS" COLUMN.
770102 / 808302 / 808602
Blade
2643 Small Hollow - Front End
633pcs.
Brush
Mark
Chamfer
Vibratory Bowl
Polish
Wash
Plug Weld
QA Clear
1
2
3
4
5
6
7
8
1
1
1
1
1
1
40
20
2
3
2
0
1
0
0

26
30
18
0
0
0
0
0
8
6
8
56
13
46
74
13
66
19
17
0
27
0
0
90
74
25
25
56
40
46
74
103
74
25
25
56
40
46
74
103
60
30
360
180
0
30
180
10800
60
120
300
2000
0
300
300
6000
1
.25
1.2
.09
0
.1
.6
1.8
75
25.25
26.2
56.09
40
46.1
74.6
104.8
672
1996
1923
898
1260
1093
675
480
74 224 8
306
480pcs.
1
1
31
TIPS FOR CAPACITY SHEET
Do not include abnormal situations
- machine goes down
- set-up time (changeover) should not be included
Use caution in computing time per pc
- each task time needs to be reviewed prior to normalization
Enter process steps, not individual operator tasks
Available time is same as that used in Takt time calculation
32
Operations Bar
Chart
32
Operation
10
Operation
20
Operation
30
Operation
40
Auto
Manual
Walk
Wait
2 shift T/T = 37 sec
Time,
sec
50
38
38
30
Determine balance
between operations
32
Operation
10
Operation
20
Operation
30
Operation
40
Auto
Manual
Walk
Wait
2 shift T/T = 37 sec
Time,
sec
50
38
38
30
Assess each operation
vs Takt time
Identifies targets
for Kaizen
35
2 shift T/T
Operation
20
Time
Auto
Manual
Walk
Defines operator /
machine interaction
33
2 shift T/T
Operation
20
Put tasks in order
they are performed
Show each manual and auto task
Time
BAR CHART SHOWS
OPERATOR/MACHINE INTERACTION
Auto
Walk
Manual
34
Operation
10
Operation
20
Operation
30
Operation
40
Auto
Manual Internal
Walk
SAMPLE BAR CHART
2 shift T/T = 37 sec
Time,
sec
45
38
30
Manual External
17
15
13
14
3
13
11
13
11
27
25
5
12
35
Bar Chart
Operations
8
6
8
13
56
13
46
74
66
19
17
90
27
0
10
20
30
40
50
60
70
80
90
100
110
B
r
u
s
h

M
a
r
k

C
h
a
m
f
e
r

V
-
B
o
w
l

P
o
l
i
s
h

W
a
s
h

P
l
u
g

W
e
l
d

Q
A

C
l
e
a
r

Operations
S
e
c
o
n
d
s

Manual Internal
Automatic
Manual External
T/T
2 Shift
74
103
56
25
25
74
40
46
30
18
40 pcs
20 pcs
30
18
36
36
OPERATIONS BAR CHART TIPS
Terminology: BAR CHART, NOT % LOAD
Times should be same as on capacity sheet
Takt time must be in RED & mark # of shifts
Use color code as shown on sample
Put total time on top of bar
- show individual times inside of corresponding bar
Label operation by name not number
Work in seconds
Best practice: Show manual and auto in sequence
1st Bar Chart: Dont normalize times
2nd Bar Chart: Normalize for 1 pc flow
Indicate batch sizes on bar chart
37
Percent
Loading Chart
Identifies targets
for Kaizen
Compares cycle
time to Takt time
0
10
20
30
40
50
60
A B C D
Cycle Time
T/T
OPERATORS
T
I
M
E
Highlights bottlenecks
or available resources
1
Time n shift T/T
Operator
A
Operator
B
Operator
C
Operator
D
Operator
E
Manual
Walk
Wait
Determines balance &
distribution between operators
Load Chart
Date: Prepared By:
Title:
Takt Time:
Cycle Time:
Load Chart
Date: Prepared By:
Title:
Takt Time:
Cycle Time:
175 seconds
159 Seconds Sub Assembly Area 5, Widget 10005
2/14/02 Mr. Oliver Operator
25
50
75
100
125
150
175
200
225
Value Add
103 Sec.
NVA
56 Sec.
TT
Operator A
Load Chart
Date: Prepared By:
Title:
Takt Time:
Cycle Time:
175 seconds
159 Seconds Sub Assembly Area 5, Widget 10005
2/14/02 Mr. Oliver Operator
25
50
75
100
125
150
175
200
225
Value Add
103 Sec.
NVA
56 Sec.
TT
Value Add
110 Sec.
NVA
25 Sec.
Value Add
135 Sec.
NVA
75 Sec.
Operator A Operator B Operator C
Load Chart
Date: Prepared By:
Title:
Takt Time:
Cycle Time:
175 seconds
159 Seconds Sub Assembly Area 5, Widget 10005
2/14/02 Mr. Oliver Operator
25
50
75
100
125
150
175
200
225
.
.
TT
Station 1 Station 2(A) Station 3
.
.
Station 2(B) Station 4 Station 5
Load Chart
Date: Prepared By:
Title:
Takt Time:
Cycle Time:
175 seconds
159 Seconds Sub AssemblyArea 5, Widget 10005
2/14/02 Mr. Oliver Operator
25
50
75
100
125
150
175
200
225
.
.
TT
Station1 Station2(A) Station3
.
.
Station2(B) Station4 Station5
Load Chart Examples
43
SAMPLE OPERATOR PERCENT
LOAD CHART
Time
n shift T/T
Operator
A
Operator
B
Operator
C
Operator
D
Operator
E
Manual
Walk
Wait
# operators
per shift
Total CT
T/T
=
44
Percent Load Chart
Operators
34
26
56
46
74
2
2
36
13
3
13
0
10
20
30
40
50
60
70
80
90
A B C D E
Operators
S
e
c
o
n
d
s

Walk
Manual External
T/T
2 Shift
Manpower = Sum of Cycle Time = 306 = 4
Takt Time 79
46
74
70
41
75
45
OPERATOR PER CENT LOAD - TIPS
Takt time must be in red & # of shifts indicated
Use same color codes as bar chart
Put total time on top of bar & individual times inside
bar
Show manpower calculation
Kaizen improvements to balance CT to T/T
- Understand the existing operator balance
- 1st attack times that exceed T/T
- Reduce walking times & utilize waiting time
- Redistribute operator work to improve balance
T/T =
60
51
45
58
43
T/T =
60
60 60 60
12
A B C D A B C D
Kaizen
Eliminate with
Kaizen
46
JT9D INDUCTION EXAMPLE
0
10
20
30
40
T/T
Stations
T
I
M
E
Cycle Time
50
60
1) Transfer work from station
to station
2) Productivity Improvements
3) Add People
47
JT9D INDUCTION EXAMPLE
0
10
20
30
40
T/T
Stations
T
I
M
E
Cycle Time
50
60
48
STANDARD WORK
COMBINATION SHEET
Visually displays manual, walking,
and waiting time of mechanic
Captures the products cycle times;
assembly, disassembly, inspection,
balancing, etc.
Compares Cycle Time to Takt Time to
insure proper capacity - one per
mechanic
49
Standard Work
Combination sheet
Work sequence of the operator,
not the part process
Recognizes walking
time of operator
One per operator
Highlights idle time,
or potential shortfall
Machine cycle
time displayed
50
STANDARD WORK COMBINATION SHEET (SWCS)
PART NUMBER OPERATION NUMBER REV. LETTER SUM. LETTER DATE TAKT TIME MANUAL
AUTOMATIC
WALK VVVVVVVVV
PART NAME DEPARTMENT NUMBER / NAME PREPARED BY WAIT
STEP DESCRIPTION OF PCS / MAN -
NO. TASK LOAD MACH MAN AUTO
WALK
TOTAL
TIME PER PIECE
USE MINUTES PER PIECE FOR STANDARD WORK DATABASE
P&W F-7837 Revised 11/97
TASK TIME: 1 LINE = MINUTES SECONDS




WALK






CAP.
51
STANDARD WORK COMBINATION SHEET (SWCS)
PART NUMBER OPERATION NUMBER REV. LETTER SUM. LETTER DATE TAKT TIME MANUAL
AUTOMATIC
WALK VVVVVVVVV
PART NAME DEPARTMENT NUMBER / NAME PREPARED BY WAIT
STEP DESCRIPTION OF PCS / MAN -
NO. TASK LOAD MACH MAN AUTO
WALK
TOTAL
TIME PER PIECE
USE MINUTES PER PIECE FOR STANDARD WORK DATABASE
P&W F-7837 Revised 11/97
TASK TIME: 1 LINE = MINUTES SECONDS




WALK






1. Fill in information
For Std. Work
Measurement Only
2. Insert tasks from
time observation
3. Fill in time and
compute total time
4. Set scale based
on total time

5. Takt time is RED line
6. Graph according to legend
CAP.
52
STANDARD WORK COMBINATION SHEET (SWCS)
PART NUMBER OPERATION NUMBER REV. LETTER SUM. LETTER DATE OPERATOR MANUAL
AUTOMATIC
WALK VVVVVVVVV
PART NAME DEPARTMENT NUMBER / NAME PREPARED BY WAIT
STEP DESCRIPTION OF PCS / MAN -
NO. TASK LOAD MACH MAN AUTO
WALK
TOTAL
TIME PER PIECE
USE MINUTES PER PIECE FOR STANDARD WORK DATABASE
P&W F-7837 Revised 11/97
TASK TIME: 1 LINE = MINUTES SECONDS




WALK






2/18/98
79 Sec. A. Parker
2643 / Small Hollow F. End
770102
1
2
3
4
5
6
7
Load Part in Mask /Q.V.
Load / Unload Part
Gage
Q.V. / Go To Mark
Load / Unload Part
Input Variable
Use Camera
1
1
1
1
1
1
1
12
8
11
3
11
6
14
6
6
1
X
5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95
T/T
70
A
TAKT TIME
Q.V. / Put Down Part 8
1
5
2
3
19
5
< >
Blade
CAP.
53
STANDARD WORK COMBINATION
SHEET - TIPS
Takt time must be recorded in top section and line
drawn in RED
Walk is not a separate task
Human time (CT = Manual + Walk + Wait) must be
continuous
SWCS should be for operator
If auto time less than T/T graph auto time to T/T line &
wrap around

------------------ -------
SWCS can be multiple pages to show detailed operator
work sequence
Use broken scale for large imbalance of task times
Do not total the auto times
Line for CT of operator should be at approximately 45 deg
T/T
0
Manual Auto
54
Standard Work
Sheet
Quality
Checks
Safety
Precautions
Standard Work
in Process
Show Machine Layout,
People & Part Flow
1
2
3
4
5
6
55
Standard Work Sheet
Scope of From Date prepared
Operations To or revised:
Quality Safety Standard Work- # of Pieces of Std. TAKT Cycle Operator
Check Precaution in-Process Work-in-Process Time Time Number
56
Standard Work Sheet
Scope of From Date prepared
Operations To or revised:
Quality Safety Standard Work- # of Pieces of Std. TAKT Cycle Operator
Check Precaution in-Process Work-in-Process Time Time Number
1. Fill in process start & finish
2. Diagram layout for
work area/cell
3. Show operator work sequence

4. Show SWIP at each work
station & record total
5. Show where inspection occurs
6. Mark location for safety precaution
7. Insert T/T
8. Insert operator CT
9. Insert operator #
/ Total operators
57
Standard Work Sheet
Scope of From Date prepared
Operations To or revised:
Quality Safety Standard Work- # of Pieces of Std. TAKT Cycle Operator
Check Precaution in-Process Work-in-Process Time Time Number
QA
Clear
Plug
Weld
Wash Polish Deburr
Vibro
Bowl
Burn
Out
EDM Brush Chamfer
Incoming
Brush
QA Clear
79 Sec. 123
2/18/98
Mark
5 306
X 2
X
2
58
STANDARD WORK SHEET - TIPS
Work sequence must be numbered
Show return trip with dashed line (no value
added)
Indicates part leaving line
Heat Treat
Does not have to be to scale, but show
distances
Operator represented by
59
MANPOWER REQUIREMENTS
Manpower to work to maximum capacity

Total human work (cycle) time based on 1 pc
Total time per pc for slowest operation
Operators Needed
per shift
=
Barriers
Contractual obligations
Operator skills
Layout
Operator willingness
Manpower required to meet customer demand
Operators Needed
per shift
Takt Time
=
Total human work (cycle) time based on 1 pc
60
Time obs.
Process
Capacity
% Load
Std work sheet
SWCS

Operation
Bar Chart

Make
Improvements
IMPLEMENTATION OF STD WORK
61
SUMMARY
Basic principles of JIT manufacturing
Takt
Flow
Pull
Standard Work Components
Takt Time
Work Sequence
Standard Work-in-Process
Standard Work Tools
Time Observation Form
Capacity by Process
Bar Chart
Per Cent Loading
Standard Work Combination Sheet
Standard Work Sheet

62
ADDITIONAL TOOLS
63
P-Q Analysis BU 263 Cell#3
0
1250
2500
3750
5000
6250
7500
8750
10000
11250
12500
7
9
4
7
0
1
8
4
0
0
0
1
8
0
8
6
0
2
8
5
5
9
0
1
7
7
0
1
0
2
8
0
8
3
0
2
8
5
6
0
0
1
8
0
8
3
1
2
8
5
6
1
0
1
8
3
9
2
0
1
8
1
5
7
2
1
8
1
5
8
2
1
8
1
5
7
4
1
8
1
5
9
4
1
7
9
5
1
3
2
8
1
5
8
3
1
8
5
4
0
0
1
Q
u
a
n
i
t
y
0.00%
20.00%
40.00%
60.00%
80.00%
100.00%
120.00%
T
o
t
a
l

%
64
PROCESS MATRIX
Part #
Machine
Part
Type
Process
794701
840001
808602
856001
770102
BT 500526
Brush Mark Chamfer
Burn
Out
Vibra
Bowl
Polish Wash
Plug
Weld
Blade
Blade
Blade
Blade
Blade
2 3 4 5 6 7 8
1
1
2 3 4
1 2
3 4
5
1
1
2
2
3
3
4
4 5
BT 007936 BT 237909 BT 505300 BT 421789 BT 511893 BT 356432 BT 111233
** All numbers used are for illustration purposes only.
65
Part Number______________
Process at a Glance
Process
Sketch
Work
Methods
Measuring
Gages
Jig or
Fixture
Cutting
Tools
Machine
T
i
m
e
Manual
Machine
Setup
Takt Time______________
Comments:
66
Spaghetti Chart
Measures the travel distance of the products and the travel
distance of the operator in order to highlight unnecessary
travel waste.
PW4000 2nd STAGE HPT VANE
PROCESS CENTERS FLOW
7,992 FT
8 WEEK LEADTIME
BEFORE
NORTH HAVEN FACILITY - 1st Floor
1,117 FT
3 WEEK LEADTIME
AFTER
67
N2-FCU Assy / I2-Line (before)
A1 A2 A3 A4 A5 A6
A7
A8
A9
A12 A10 A11 A15 A14 A13
B3
B2
B1
C1
D1 D2
WIP
INSPECTION R/M
P.P BANDING M/C
CREW SIZE = 21
STANDARD WORK SUMMARY(C1)
68
69
70
71
72
* Collect Current Demand Data by Model
- Determine Available Time to Produce Demand
4 Establish TAKT Time
^ Collect Current Work Content Times
= Complete Standard Work Combination Sheet and Create Load Chart
= Eliminate Waste by Separating Value-added and Non-value-added Activities
Redistribute Work Content to Meet TAKT Time and Create New Load Chart
Establish Standard Work-in-process
Verify New Work Content Times and Redistribute Again as Necessary
O Establish Method Sheets for Each Operation to Document Standard Method
Steps to Implement Standard Work
73
74
75
N-2 FCU Assy / I 2 - Line (after)
A1
A2 A3
A4
A5 A6
A7
A8
A9 A12
A10 A11
A15 A14 A13
B3
B2
B1
D1
C1
WIP
INSPECTION R/M
P.P BANDING M/C
CREW SIZE = 11
STANDARD WORK SUMMARY(C2)