This document provides an overview of standard work and the process of standardization. It defines standard work as an agreed-upon set of work procedures that establish the best and most reliable methods and sequences for each process and worker. The document outlines the key elements of standard work, including takt time, standard work sequence, and standard work-in-process inventory. It also describes the importance of clear standards and standard work, and the four steps to implement standard work: creating a process capacity table, standard work combination table, work methods chart, and standard work chart. The goal of standard work is to maximize performance while minimizing waste.

1. © Lean & Mean Consulting. All rights reserved. 2015© Lean & Mean Consulting. All rights reserved. 2016
09/ 16Standard Operations
Standard Work & Process of Standardization
World-Class Standards & Best Practices of Operational Excellence

2. World-Class Standards & Best Practices of Operational Excellence
© Lean & Mean Consulting. All rights reserved. 2016
LEAN Management Academy - Outline
Knowledge & Expertise / Editable Training Presentations / 16 Modules

3. 3
Learning Objectives
1. Understand the importance of standardization in
Lean Production System
2. Identify the key benefits and applications of
standards and standard work
3. Acquire knowledge of standard work concepts,
principles and tools to maximize performance and
minimize waste

4. 4
Contents
1. Introduction
2. Standardization
3. Standards
4. Standard Work
5. Implementing & Sustaining Standard Work
6. Improving Standard Work

5. 1
Standard Work / Process of Standardization
Module. 09

6. 6
What Is Standard Work?
 Standard work is one of the most powerful but one of the most
underutilized of the lean tools.
 Documenting the current best methods, standardized work forms the baseline
for kaizen and 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.
 Establishing standard 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 become familiar with these forms and why it will be
difficult to make your lean implementations “stick” without standardized work.

7. 7
What Is Standard Work?
 Standard work establishes the best and most reliable
methods and sequences for each process and each worker
Materials and
parts
MeasurementsPeopleMethodsMachines
(equipment)
Feed in
materials
Ship to customers

8. 8
Standard Work Forms the Baseline for
Continuous Improvement
Kaizen
StandardizationS
DC
A
P
DC
A
Kaizen
StandardizationS
DC
A
P
DC
A

9. 9
The Framework of Standardization
The practice of setting,
communicating, following, and
improving standards and standard
work
A rule or example that
provides clear explanations
A set of work procedures that
establish the best and most
reliable methods and
sequences for each process
and each worker
Standardization
Standard Work
Standards

10. 10
What is Standardization?
Standardization is the practice of setting, communicating, following,
and improving standards
 A standard provides the baseline upon which to measure the
results of continuous improvement activities
 If better results are obtained with the improved process, then the
standard can be changed
 The process of continually improving the standards is the path to
reliable methods
 Everyone must practice the standard consistently before
standardization truly exists

11. 11
Ladder of Standardization
6. Improvement of management methods: Information
5. Standardization of objects: Materials
4. Building standards into equipment: Production equipment,
computers, etc.
3. Standards for jigs, tools and alarm devices: Measurement
2. Standards manuals to clarify work sequences: Methods
1. Procedures explained by veteran workers: People
Step-by-step
progress to
higher levels of
standardization
Direction of improvement

12. 12
Documents in Manufacturing
Work Standards
• Work instructions
• Operation drawings
• Operation instruction sheets
• Process conditions sheets
• Quality control sheets
• Tooling layout drawings
• etc.
Job Instruction
• Job breakdown sheet
• Cross training skills matrix
• Operation instruction sheets
• Etc.
Work Study/Improvement
• Time study
• Motion study
• Work element analysis
• etc.
Standardized Work
• Process capacity table
• Work combination chart
• Standardized work chart

13. 13
Standard Work Overview
3 Requirements
3 Elements
3 Forms
Actual Standard
Work in TPS
• Repetitive cyclical work
• High process and part quality
• Low equipment downtime
• Process capacity table
• Standardized work combination chart
• Standardize work chart
• Takt time
• Work sequence
• Standard work-in-process
Definition: A document centered around human motion that combines the
elements of a job into the most effective sequence without waste to achieve
the most efficient level of production.
If these forms and conditions are not met then it is not true standard work. The
task is probably best suited by some form of work instruction or other standard.

14. 3
Standard Work / Process of Standardization
Module. 09

15. 15
Standard – it is a formal, written definition of the
best knowledge and method of work,
recognized and depicted at any given
moment for satisfaction of customer
requirements.
Standard provides clear explanations!
What is a Standard?

16. 16
Standards
 Basic features of standards:
 Present the best, easiest and safest method of doing work
 Constitute the best method of preserving knowledge and
competence
 Constitute the benchmark for work evaluation
 Show the cause and effect relation
 Give basis for maintaining current level and development
 Are factual, simple and clear
 Constitute basis for training
 Are the basis for inspection and diagnosis
 Are the means to prevent mistakes and minimize variability

17. 17
 Regulations
 Quality Standards
 Specifications
 Technical Standards
Types of Standards
 Process Standards
 Manuals
 Notices
 Memos

18. 18
Three Steps to Establish Standards
1. Create the
standard
2. Stabilize the
standard
3. Improve the
standard

19. 19
 Define the problem
 Identify abnormal conditions
 Define the standard required for normal performance
 Gain team agreement on the standard
 Implement the standard – communicate and train as needed
 Monitor and follow up
Step 1: Create the Standard

20. 4
Standard Work / Process of Standardization
Module. 09

21. 21
What is Standard Work?
Standard work is an agreed-upon set of work procedures that
establish the best and most reliable methods and sequences
for each process and each worker
 Standard work aims to maximize performance while
minimizing waste in each person’s operation and workload
 Standard work is the fluctuating level of optimum work to be
done by people and machines each day to meet customer
demand

22. 22
Standard Work
 Prerequisites for standard work
 5S and visual controls
 Quick changeover
 Mistake-proofing
 Total productive maintenance
 Human automation
 Cellular manufacturing
 Pull production with kanban
 Line balancing

23. 23
Six Characteristics of Standard Work
• Clear
• Correct
• Concise
• Communicated
• Current
• Complete
6
Characteristics
of Standard
Work

24. 24
Standard Work Must be Clear
 Standard work has to be clear so that it can be followed
correctly.
 What is clear to one person may not be clear to another.
 We need to ensure that users and auditors understand
standard work the same way.
 Extra jargon, verbosity, vague description or poor formatting
should be avoided.
•Clear
•Correct
•Concise
•Communicated
•Current
•Complete
6
Characteristics
of Standard
Work

25. 5
Standard Work / Process of Standardization
Module. 09

26. 26
 Work point of view:
 Work is centered around human motion
 Work is done the same way each time
 Small variation in work content
 Equipment point of view:
 Minimal trouble with machines
 Minimal fluctuation in production volume
 Quality point of view:
 Minimal trouble in process quality
 Minimal trouble in parts and material
Ideal Conditions for Standard Work

27. 27
Three Elements of Standard Work
Standard
Work-In-Process
Inventory
Takt-Time
Standard
Work
Sequence

28. 28
 Standard work consists of three elements:
 Takt time
 Matches the time to produce a part or finished product with the rate of
sales. It is the basis for determining workforce size and work allocation
 Standard work sequence
 The order in which a worker performs tasks for various processes
 Standard work-in-process inventory
 The minimum number of parts, including units in machines, required to keep
a cell or process moving
Three Elements of Standard Work

29. Standard Work / Process of Standardization
Module. 09

30. 30
Standard Work Sequence
Good
Poor

31. 31
Four Steps to Standard Work
1. Create a Process Capacity Table
2. Create a Standard Work Combination Table
3. Create a Work Methods Chart
4. Create a Standard Work Chart

32. 32
Step 1: Process Capacity Table

33. 33
Step 4: Standard Work Chart: example

34. 34
 Create a drawing of the operations in the cell and enter their
sequence and description
 Enter the quality checkpoints
 Enter the safety checkpoints
 Enter the WIP
 Enter the Takt time and the net cycle time
 Enter the amount of standard WIP
 Enter the breakdown numbers to indicate different
operations in the cell and total number of operators
Step 4: Standard Work Chart

35. 35
Improving Standard Work
 Areas for improvement:
 Flow of materials
 Shifting from specialization to multi-skilled lines and operators
 Improvements in motion
 Establishing rules for operations
 Equipment
 Separation of people and machines
 Preventing defects
 Eliminating walking
 Shift from one-handed to two-handed tasks
 Placement of parts
 Improvements in motion are among the most important changes.

36. 36© Lean & Mean Consulting. All rights reserved. 2016