tw i and standard work

8/3/2019 Tw i and Standard Work

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TWI and Standard Work

www.TWI-Institute.org



Standardized Work vs.

Work Standards

Work Standards Definitions*:

Quality, Safety and Environmental StandardsFit and Finish – Not detailed in Standardized Work

Established to follow state and federal regulations may be identified as the safety cross.

Standard SpecificationsTechnical Information– Not detailed in Standardized Work

Corrective Action information – typically handled outside the Standardized Work for the operator

Standard Procedures

Standards should be visually defined and self explanatory– Not detailed in Standardized Work

*The Toyota Way Fieldbook, p 118-122 Liker & Meier, 2006

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Standardized Work

graphical structure best utilized for situations with multiple

operators or an automatic machine cycle

begins life as and

4



STANDARDIZED WORKCHART

PROCESS Cycle Time TAKT TimeSAFETY QUALITY IN PROCESS

Gl ost Ki ln Op era tor Cycl e 3 0-m in ute s 1-cycl e / 90-

minutes

Element

Number

Description Work Time Walk

TimeWORK AREA LAYOUT

1 Walkto GK #3 Exit 1.0

2 Discharge Car from GK#3 5.0

3 Discharge Car from GK#4 5.0 1.2

4 Record GK#4 car numbersan d

temps1.0 0.7

5 Charge GK#4 5.0 0.3

6 Charge GK#3 5.0 1.0

7 Record GK#3 car numbersan d

temps1.0 0.6

8 Return to loading 0.6

Total (min): 22 5.4COMMENTS:

S af et y: Use h ig h t em p g lo ve s, pu sh er t o m ove ca rs a nd be mi nd fu l f or oi l y/ sl ic ksu rf ac esQ ua li t y: I nsp ec t ki l n ca rs a n d rep ai r d owne d ware an d ref ra ct ory. Use c are no t t o da ma ge glaz e o f u nf ired wa re

GK#4

GK#3

ENTRANCE

ENTRANCE

EXIT

EXIT

1, 8

2

3

4

5

6

7

Panel Board

Panel Board

Load Station

Load Station

Standardized Work

combined sheets best usedwith single operator and no

automatic cycle

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How do you teach operators to do the

Standardized Work Elements?

• TWI implements Job Instruction with the

proven 4 step methodology.

• Traditional Lean Implementations deliver

‘Standard Work’ forms and rely on a variety of

work standards to teach the operators.

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TPS/TWI Job Instruction(how to do/teach the job)

Job Instruction Breakdown

JOB INSTRUCTION BREAKDOWNElement Description:Charge GK #4

SAFETY QUALITY IN PROCESS

Element Number: 5 PARTS:Tools and Materials:High Temp Gloves

# IMPORTANT STEPS KEY POINTS REASONS ILLUSTRATIONS

A logical segment of the operation whensomething happens to advance the work.

Anything ina step that might—

1.Makeor break thejob2.Injurethe worker3.Makethe work easier to do

(“knack”, “trick”, special timing,bit of special information)

Reasons for Key Points

1Open doors

1. Use high temp gloves2. Turn clockwise3. Swing past floor pit

1. Very hot2. Opens in reverse3. Car will wreck

2 Move t rans fer over 1. Lat ch dogs down 1. Mak es t rans fer eas ier

3 Push car onto transfer1. Move slowly2. Fix downed ware / refractory

1. Ware quality2. Ware quality

4Push transfer back intokiln

1. Ensure dog is latched1. Car will not push intokiln

5 Close doors

1. Use high temp gloves2. Turn counterclockwise

1. Very hot2. Closes reverse

6 Check hydraulic pressure1. Needle in green ofgauge

1. Ensures hydraulicpressure to push

7

8

9

10

NOTES:Safety: wear hard hat when moving kiln cars. Notify supervisors if car quality is in question (structurally)

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TWI LEAN EXAMPLE-Ceramic Kiln Operator

• Operators struggling to keep up with process.Ergonomic issues noted.

• Union-Management Improvement team

assembled to investigate.• There is a high level of variation between

operators and shifts

• An excessive amount of walking was noted.

• Operators were not conducting routineprocess controls

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Stabilization

• Included others indeveloping Job Instruction

• Train all operators to oneprocedure

• Refocus on quality at thesource versus just keepingup

• Reduce noise by eliminatingvariation

No. __________

JOB INSTRUCTION BREAKDOWN SHEET

Operation: Glost Kiln Operator Cycle _

Parts: None _

Tools & Materials: Kiln Gloves _

IMPORTANT STEPS KEY POINTS REASONS

A logical segment of the operation when

something happensto advance the work.

Anything in a step that might—

1.Make or break the job2.Injure the worker

3.Make the work easier to do, i.e. “knack”,“trick”, special timi ng, bit of special

information

Reasons for the key points

1. Discharge GK #3 1. Use kiln gloves2. Pull at correct time

1. Burn hazard2. Kiln control

2. Charge GK #31. Fix downed ware2. Do not slam transfer

1. Defect prevention2. Defect prevention

3. Record car data

4. Check kilntemperatures

1. Call Ceramic Tech if50°F delta in zones

1. Proper kiln control

5. Charge GK #3

1. Fix downed ware

2. Do not slam transfer

1. Defect prevention

2. Defect prevention

6. Discharge GK #31. Use kiln gloves2. Pull at correct time

1. Burn hazard2. Kiln control

7. Record car data

8. Check kilntemperatures

1. Call Ceramic Tech if50°F delta in zones

1. Proper kiln control

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Identify Improvements(JM Breakdown)PRODUCT: Glost Ware MADE BY: Lanno DATE:

OPERATIONS: Glost Kiln Operator DEPARTMENT: Lean Team

CURRENT/PROPOSEDMETHOD DETAILS

D i s t a n c e

t r a v e l e d

i n f e e t

REMARKS

W H Y -

W H E R E

W H E N

W H O

H O W

IDEAS

E l i m i n a t e

C o m b i n e

R e a r r a n g

S i m p l i f y

TIME/TOLERANCE/

REJECTS/SAFETYWrite them down, don’t try to remember.

1 Discharge GK #4 x

2 Walk to control panel 148 45 x Eliminate special trip to record this data point x

3 Record car number x xCan bar codes be used to eliminate this manualstep?

x

4 Walk to control panel 145 40 x Eliminate trips to control panels (back tracking) x

5 Check kiln readings x xCan kiln check be put on a 90-minute check asroutine?

x

6 Walk to GK #4 loading 137 35 x Eliminate trips to control panels (back tracking) x

7 Load car

8 Walk to GK #4 entrance 135 35 x x Item #5 x

9 Charge ki ln

10 Walk to control panel 41 15 x Item #6

11 Record car number

12 Walk to GK #3 242 60 x x x

13 Discharge car

14 Walk to control panel 138 45 x Item #6

15 Record number x x Item #3 x

16 Walk to GK #4 137 35

17 Load car

18 Walk to GK #3 236 60

19 Charge kiln

20 Walk to control panel 99 25 x Item #6 x

21 Record data

22 Kiln check x x

23 Walk to control panel 145 60 x Item #6 x

24 Record kiln data x Install ANDONs to eliminate 90-minute kiln checks x

25 … … …

2024-ft 555-seconds (travel only) 10



Improvements Into Action

• Andon installed on kilns to alarm whentemperature deltas were poorly impacting the kiln

profile

• Worked with Planning on procedure to change kilncycle, therefore walk patterns were minimized

• Focus on kiln car condition and repair with time

savings. Direct correlation to first pass yield

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Kiln Operator Example (SW Chart)STANDARDIZED WORKCHART

PROCESS Cycle Time TAKT TimeSAFETY QUALITY IN PROCESS

Glost Kiln Operator Cycle 30-minutes 1-cycle / 90-minutes

ElementNumber

Description Work Time WalkTime

WORK AREA LAYOUT

1 Walk to GK #3 Exit 1.0

2 Discharge Car from GK#3 5.0

3 Discharge Car from GK#4 5.0 1.2

4 Record GK#4 car numbers

and temps

1.0 0.7

5 Charge GK#4 5.0 0.3

6 Charge GK#3 5.0 1.0

7 Record GK#3 car numbers

and temps1.0 0.6

8 Return to loading 0.6

Total (min): 22 5.4COMMENTS:

Safety: Use high temp gloves, pusher to move cars and be mindful for oily/slick surfacesQuality: Inspect kiln cars and repair downed ware and refractory. Use care not to damage glaze of unfired ware

GK#4

GK#3

ENTRANCE

ENTRANCE

EXIT

EXIT

1, 8

2

3

4

5

6

7

Panel Board

Panel Board

Load Station

Load Station

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Kiln Operator Example (Element JI)JOB INSTRUCTION BREAKDOWN

Element Description:

Charge GK #4

SAFETY QUALITY IN PROCESS

Element Number: 5 PARTS:Tools and Materials:High Temp Gloves

# IMPORTANT STEPS KEY POINTS REASONS ILLUSTRATIONS

A logical segment of the operation whensomething happens to advance the work.

Anything in a step that might—1.Make or break the job2.Injure the worker3.Make the work easier to do

(“knack”, “trick”, special timing,bit of s pecial information)

Reasons for Key Points

1 Open doors1. Use high temp gloves

2. Turn clockwise3. Swing past floor pit

1. Very hot

2. Opens in reverse3. Car will wreck

2 Move transfer over 1. Latch dogs down 1. Makes transfer easier

3 Push car onto transfer

1. Move slowly

2. Fix downed ware / refractory

1. Ware quality

2. Ware quality

4 Push transfer back into kiln 1. Ensure dog is latched 1. Car will not push into kiln

5 Close doors1. Use high temp gloves2. Turn counter clockwise

1. Very hot2. Closes reverse

6 Check hydraulic p ressure 1. Needle in green ofgauge

1. Ensures hydraulicpressure to push

7

8

9

10

NOTES:Safety: wear hard hat when moving kiln cars. Notify supervisors if car quality is in question (structurally)

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Kiln Operator Example (Impact)

Before After Savings Reduced%

Distance

Walked

per Shift

16,192-ft 5,745-ft 10,447-ft 65%

2.8-miles 1.0-mile 1.8-miles 65%Time

Walking

per shift

73-min 27-min 46-min 63%

Time saved allowed Kiln Operators to repair kiln cars

resulting in higher First Pass Yields

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TWI/Lean Integration

• Stabilize your work method

– Use Job Instruction and Standardized Work

• Evaluate and improve your work method

– Use Job Methods with Lean techniques

• Stabilize your improved work method – Use Job Instruction and Standardized Work

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tw i and standard work

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