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Standard Work

Standard Work. Coverage. What is Standard Work? Types of Standard Work? Groundwork for Standard Work. What is Poka-Yoke? How to create Standards? Simulation exercise. Origin of Standard Work.

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Standard Work

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  1. Standard Work

  2. Coverage • What is Standard Work? • Types of Standard Work? • Groundwork for Standard Work. • What is Poka-Yoke? • How to create Standards? • Simulation exercise

  3. Origin of Standard Work The creation of standardize work initially began with the invention & the eventual perfection of interchangeable parts. History Points: Early Venetian craftsmen understood the benefits of standard or interchangeable parts when building ships of war. Eli Whitney, famous for the cotton gin perfected the concept of interchangeable parts when he designed and built muskets for the U.S. army.

  4. Definition • Standard work: It is the proclamation of the most waste free procedure, through the best combination of people and equipment.

  5. Standard work and Improvement • Consistent process gets consistent results. • Repeatability and reliability lead to continuous improvement.

  6. Benefits to having standard procedures in place -- • Consistent quality • Easier to learn a new position • Easier to train new people • Reduces cost • Provides a baseline for improvement • Your expertise and experience is reflected in the standard • Everyone is involved in choosing “one best method”

  7. Laying the Groundwork for Standard work • 6S and visual control • Elimination of any waste • Analyzing of the work itself

  8. Types of standards • Those based on authority, custom, or consensus that continually evolve over time. • Those based on scientific data or experience that change, but more slowly. • Those based on technical specifications that tend to remain constant.

  9. Standards and beyond • Done after the process has been “value-added” and “improved”. • Capture and utilize the “best” method to maintain the “value-added” process steps. • Make it with user-friendly language, pictures, or symbols to communicate the standard. • Build in quality, safety, and expectations into the work

  10. Standards and Beyond • People will continually think of ways to improve the way they do their work, so….. • The culture must support creative problem solving if standardization is to be achieved and flexibility of standard work is to be possible.

  11. General Examples

  12. Poka-yoke • Any mechanism that either prevents a mistake from being made or makes the mistake obvious at a glance. • A color coded tape is used to measure a child in the emergency room. • Each color code shows what properly sized supplies to used based on height. Supplies are in same color coded packets.  The tape also indicates correct  dosages of drugs.

  13. Standardize coding procedures to correctly capture diagnose for billing and research.

  14. Standardize procedures for refilling and placement in a stockroom

  15. Standardize packaging of surgery instruments for specific surgeries.

  16. Others • Standardize procedure for applicant interviews • Standardize checklist for new employee orientation

  17. Simulation Paper airplane construction

  18. At each table: • One -- data collector • Four -- workers • Supplies needed • Data collection sheet and marker • Session 1: Plain purple paper • Session 2: Lined white paper • Session 3: Lined and Numbered Yellow paper

  19. Count how many quality airplanes do you have at your table? What did you find out?

  20. Session 1 – Construct 5 airplanes • Using the plain purple paper • Each worker constructs 5 planes • Data collector • How much time did each worker take to make the 5 planes? Record the average in Session 1 • Count how many of the planes do not look like the picture. These are defects! Record the total. Be very critical ! • Oh by the way --- it has to look like this

  21. Session 2 – limited • Lets try this again --- Data Collector pick up the lined white paper and distribute 5 sheets to each worker. • Construct five airplanes following the instructions provided and new sheets. • Data collectors --- record the time information under session 2. Remember the planes must look like

  22. Session 3 – Standardize work • Lets try this one more time --- Data Collectors pick up the Lined and numbered yellow sheets and distribute 5 sheets to each worker. • Construct five airplanes with improved sheets and the following pictures.

  23. Fold along diagonal lines

  24. Open up and push in from the sides.

  25. Fold nose down.

  26. Folding the wings. Fold along the dotted lines.

  27. Conclusion: • Symbols, checklist, simple language • Use pictures where possible • Color codes • Same location • Audits

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