Standard Work Documentation

Course Description
Standard Work (also called Standardized Work) is the cornerstone in the Toyota Production System (TPS) house. It is an essential building block of a Lean Enterprise.  Standardized Work is different from standardization or work standards and is not yet well understood by most organizations pursuing Lean.

When properly documented, it not only provides a tool for managing Safety, Quality, Delivery and Cost (SQDC) but also a baseline for future kaizen activity.  It is defined as the most effective combination of manpower, material, and machinery and it is built on the three elements of takt time, work sequence and standard work in process.

QSG’s Standardized Work course will help participants:

  • Simplify training of new workers
  • Document processes in order to reduce variability
  • Reduce safety and quality problems
  • Develop a foundation for continuous improvement
  • Implement process level visual management

Who Should Attend?
This course is designed to give you the knowledge and practice needed to begin using Standardized Work as part of your Lean manufacturing or process improvement effort.  The target audience includes:

  • Managers, engineers, supervisors, team leaders, operators
  • Any industry with repeatable manual operations

This course is designated as a 200 level class and is appropriate for practitioners or as a refresher for instructors.

Course Outline
This course will be a “teach & do” format where you will learn in class how to create Standardized Work through a combination of exercises, case studies and practice with Standard Work documents.  The three elements of Standardized Work (Takt Time, Work Sequence, and Standardized Work in Process) will be taught.

The course covers:

  • Standard Work Overview
  • The difference between Standard Work, standardization and work standards
  • The link between TWI, Job Instruction and Standard Work
  • Takt time calculation
  • How to perform direct process observation for measuring cycle times
  • Defining work sequence
  • Balancing to take time
  • Determining where and how much Standard Work in Process (SWIP) is needed
  • Using the Table of Production Capacity by Process
  • Assessing quality, method and equipment to determine whether the line is capable of Standard Work
  • Creating Standardized Work Combination Sheets (SWCS)
  • Creating Standardized Work Sheets (SWS)
  • Visual Management and auditing and improving Standard Work
  • Kaizen based on Standard Work

Learning Objectives
Participants will, upon completion of this course, successfully demonstrate their ability to:

  • Explain the difference between standardization and Standardized Work (SW)
  • Explain the importance of SW for a Lean manufacturing
  • Create a Combination Sheet
  • Create a SW Sheet
  • Use a Table of Production Capacity by Process
  • Use SW documents for training
  • Use SW documents to find kaizen opportunities
  • Use SW for documenting and sustaining kaizen

Course Format
8 hours
Combination lecture and classroom exercises
Available at QSG’s training facilities and on-site at your organization

Recommended Reading
The Toyota Way by Jeffrey Liker

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