ieng 451 standardized work. benefits of standardization – process stability – stability means...
TRANSCRIPT
IENG 451
Standardized Work
Standardized Work
• Benefits of Standardization– Process stability – stability means repeatability– Clear stop and start points for each process– Organizational learning– Employee involvement and poka-yoke (error
proofing)– Kaizen – continuous improvement– Training
Sources of Instability
• Quality problems with incoming parts• Problems with machines, jigs• Parts shortages• Waiting for a part• Safety problems
Elements of Standard Work
• Takt time • Work sequence • In-process stock
• Goal is to synchronous Takt time and cycle time
Elements of Standard Work
• Work sequence – Pick up part– Walk to machine– Place part on machine – Machine process part – Take part to next machine
Elements of Standard Work
• In-process stock– Minimum number of unfinished parts required for
operator to complete the process without standing in front of a machine
– Quality checks require additional in-process– Temperatures must fall for next operation (more)– Machinery cycles automatically (more)
Production Capacity Chart
𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦=𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑜𝑛𝑡𝑖𝑚𝑒𝑝𝑒𝑟 h𝑠 𝑖𝑓𝑡
𝑝𝑟𝑜𝑐𝑒𝑠𝑠 𝑡𝑖𝑚𝑒+𝑠𝑒𝑡𝑢𝑝𝑡𝑖𝑚𝑒 / 𝑖𝑛𝑡𝑒𝑟𝑣𝑎𝑙No Name M/C
Man Time
Mach Time
TimeTo comp.
Inter changes Capacity
Time tochange
Basic Operation Time Tool Changes
3MIL 1764 Machine face
1 25 28 100 60 965
Standard Work Table
Standard Work Chart
Job Element Sheets
Line balancing
1 2 3 4 5 6 Station
time
1 2 3 4 5 6 Station
time
Overall vs Individual Efficiency
• Goldratt – Drum, Buffer, Rope – Identify bottlenecks– Exploit bottlenecks– Elevate bottlenecks
– Baseball cap factory
Standardized Work and Kaizen
• Guidelines for economy of motion (IE 311, 321)• Guidelines for layout • Guidelines for tools/jigs
Standardized Work and Kaizen
• Guidelines for economy of motion (IE 311, 321)– Hand movements symmetrical and current– Light work – Done in a strong circle– Keep hands free
• Guidelines for layout • Guidelines for tools/jigs
Standardized Work and Kaizen
• Guidelines for economy of motion (IE 311, 321)• Guidelines for layout (IE 471, 475)– Use gravity – Horizontal vs vertical movement– Place tools and materials for easy access – U-cells
• Guidelines for tools/jigs
Standardized Work and Kaizen
• Guidelines for economy of motion (IE 311, 321)• Guidelines for layout (IE 471, 475)• Guidelines for tools/jigs (IE 475)– Eliminate manual holding– Use ergonomic tools – Combine tools where possible
Common Layouts
• Job Shop • Cells • Assembly Line
• Strategies – Chase – Level– Mixed