The first book in The One-Day Expert series detailed the initial steps that Thomas, a young, high-potential plant manager in an industrial group, took to assess his plant’s situation through measurement of operators’ performance. The second book in the series, Implementing Standardized Work: Writing Standardized Work Forms focuses on the next step of this assessment—writing Standardized Work forms to help identify variability and waste.
The book uses numerous examples, charts, and drawings to illustrate the interaction between operator, machine, and material. Besides process analysis, the book discusses process analysis charts, Standardized Work charts, Standardized Work combination tables, and operator work instructions. It also:
Since an operation can only be standardized if it is repeatable, the most important requirement for a real application of Standardized Work is minimum stability in the process. The book explains how to estimate the stability level of a process by performing process analysis. It also presents a multistage bar called Yamazumihyo to help you perform your own process analysis.
After reading this book you will understand how to use Standardized Work forms as the starting point to establishing a safe and ergonomic work place that delivers quality products in an efficient manner.
"We Already Have Standards!"
On Which Tasks Can Standardized Work Forms Be Written?
Task One: Group Forming
Task Two: Team Organization
Task Three: Facilitator Gives Job Instructions for Operators
Task Four: Teams List the Detailed Steps on Flipcharts
Task Five: Facilitator and All Teams Determine Measurement Steps and Measurement Points
Task Six: Each Team to Perform 20 Reps
Introducing the Four Standardized Work Documents
The First Element of Standardized Work Forms: Takt Time
The Second Element of Standardized Work Forms: Job Sequence
The Third Element of Standardized Work Forms: Standardized Work in Process (SWIP)
The Fourth Element of Standardized Work Forms: Key Points
Writing the Forms
Initiation to the Yamazumihyo or Process Analysis Chart
Writing the Three Remaining Standardized Work Forms
Shop Floor Application