Standard Work 101 with Free Download

“Where there is no Standard there can be no Kaizen“

~ Ohno

Standard work is defined as:

Detailed definition of the most efficient method to produce a product (or perform a service) at a balanced flow to achieve a desired output rate. It breaks down the work into elements, which are sequenced, organized and repeatedly followed.

Each step in the process should be defined and must be performed repeatedly in the same manner. Any variations in the process will most likely increase cycle time and cause quality issues. It typically describes how a process should consistently be executed and documents current ‘best practices.’ It provides a baseline from which a better approach can be developed, allowing continuous improvement methods to leverage learning. Three necessary components in standard work are (1) takt time, (2) cycle time and (3) SWIP (Standard Work-in-Progress).

Developing Standard Work is one of the more difficult Lean Six Sigma disciplines; however, if efficiently developed, it should allow virtually anyone to perform the work without any variance in the desired output.

Although its a cornerstone of the Toyota Production System it’s typically lacking in most organisations. It is normally broken down on at least two documents

1. a Standard Work Sheet
2. the Standard Work Combination Sheet

Standard Work is the method, and thereby you have the four Ms of manufacturing (manpower, material, machinery, methods). Standard Work is only “the most effective” until the standard is improved. This is done through a continuous process called kaizen.

As Jon Miller states:

For a process that does not repeat or is too variable it may not be possible to establish Standard Work according to these conditions (takt time is not meaningful, work sequence varies, Standard WIP varies). In this case, eliminating the variability or standardizing the process and creating a repetitive flow is the first step in kaizen.

He also suggests that 12 questions are asked:

1. What is the standard?
2. How do we develop a standard?
3. How clear is the standard to those doing the work?
4. How clear is the standard to those not doing the work?
5. What is our performance against the standard?
6. Why are we not performing to the standard?
7. Why are we performing above the standard?
8. What are we doing to meet the standard?
9. What can we do to improve the current condition?
10. How can we make the abnormal condition more immediately visual?
11. Why do you think I asked you these questions?
12. What other questions would you have liked me to have asked?

It has a number of advantages:

• Simplicity in ensuring a uniform quality outcome
• Simplicity in troubleshooting
• Simplicity in work improvement
• Simplicity in job improvement
• Simplicity in determining fair pay
• Simplicity in job training
• Simplicity in hiring and transmission of best practices
• Simplicity in communication

I would also add that it assists in reducing human error, a point elaborated on here.

Click here to download a presentation and example forms on Standard Work

What are your experiences with Standard Work? Leave your comments below.

Related articles

• Toyota Way Fieldbook (Part 4) (leanbuilder.blogspot.com)
• Leadership Standard Work (lssacademy.com)
• 7 steps to break free form perfectionism. (imperfectaction.com)
• Six Sigma Blogs: Lean and other Six Sigma Certification (blogs.isixsigma.com)
• Six Sigma Blogs: The 1.5 Shift – Time For A Paradigm Shift? (blogs.isixsigma.com)
• How Do You Look At Problems? (theleanthinker.com)
• Gemba Academy Preview: Calculating Takt Time (gembapantarei.com)
• Six Sigma Blogs: Building Trust Through Being Personable (blogs.isixsigma.com)
• Let’s Define Lean Manufacturing (learnsigma.com)
• Book Talk: The Ultimate Improvement Cycle (leaninsider.productivitypress.com)
• Go See the Visual Management Blog (gembapantarei.com)
• Six Sigma Blogs: Survey: Six Sigma and the Economy (sixsigmacompanies.com)
• Six Sigma Blogs: My journey towards Lean (blogs.isixsigma.com)
• 5S Overview Video (gembapantarei.com)
• Lean Healthcare in Ohio (leanblog.org)
• Evolving Excellence: Buying Utopia (www.evolvingexcellence.com/blog)
• The 5P Pyramid–Level 3 (kaizencurmudgeon.blogspot.com)

 Enjoy this post? Be sure to subscribe!