Standardized work
• Need for a system in place to solve the problem of occurrence.
1. The basic requirement for a successful plant operation is to have a system in place to solve problems as and when it arises.
2. Find the right people to lead this system.
• “How long has a skipper got to react if he spots a problem?” And “How long has a manager got to react if a quality problem arises?”
• The reaction time on any problem by Supervisor will be quicker than the plant manager who has to wait for a report to analyze the situation. The Supervisor / Operators need to have a process for correcting problems as and when they arise. It is ‘how’ a person does it and the results obtained which matters.
• It is like wartime, every time you develop
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In documenting the current practice, Standardized work forms the baseline for continuous improvement. Once a single standard gets improved; the new standard becomes the baseline for future improvements. Improvement in standardized work is a continuous process. Standardized process has 3 elements – a) Takt time – time taken for the end product to meet customer demand, b) work sequence – Operator to perform tasks within takt time, and c) Standard inventory – standard inventory required to be kept to ensure smooth operation …show more content…
Standardized work focuses on 5w and 1 h. 5w (who, what, when, where, and why) – who operates the process, what does final product look and quality checks, when will it be ready, where to complete the process, why this step essential? 1 h (how) – “how” is the process to follow the time and resource. Overall the process should be smooth. Standardized work is best practices known and which are put in place by documenting the process. Standardized work is to ensure optimization of productivity, safety and quality. The goal of standardization is to ensure all 3 i.e. productivity, safety and quality are met in highest standard. Standardized work can be defined as sequence of job functions organized efficiently and followed by an operator repeatedly. The process of standardized work’s ultimate aim is to achieve kaizen. If there is no change or progress in standardized work, then the plant is in regression.
As Taiichi Ohno rightly says – “People don’t go to Toyota to ‘work’, they go there to think”. “where there is no standard, there can be no kaizen”, and “Improvement is endless and
A standard is: 'an explicit statement defining a desired level of performance'. It describes what should be done, who should be doing it, when it should be done and what records should be kept. Standards do not describe how a task should be carried out, as this is described in national or service operational policies or procedures.
The fourth chapter is titled “Standardize Work.” The theme is “to identify how the work is well defined and how the effective team effort is exerted on the maintenance of the same repetitive work in sequence”. Thus, the standardization and the effort towards lean production is important (Ballé and Ballé).
Standardization: Set of predefined specifications, rules or features that manufactures or producers need to follow when they make/produce the products/goods or components of it. Example- MacDonalds set standardization for each of its menu items like size, weight, food value etc. So, each food item need to prepare according to predefined standard.
“ISO is commonly known as ‘International Organization for Standardization’, the ISO 9001:2000 standard is used for quality systems audited by outside auditors. This standard is applicable for manufacturing companies not only for software. This standard is given based on the documentation, design, production, testing, servicing and other processes.” (Testing Excellence.com, 2009).
Toyota is making only "what is needed, when it is needed, and in the amount needed. Toyota is using impute from workers and their culture encourages employees to learn from their mistakes and successes and failures of each other.
Toyota is often criticised for better at imitation than invention. As compare to its rivals Toyota focussed more on the factory floor rather than showroom i.e. process innovation rather than on product innovation.
At Toyota workers are encouraged every single day to come up with improvement suggestions. And as their new ideas are tested, accepted and implemented the standard worksheets are updated.
The British Standard Institute characterizes work research as a general term for procedures especially those of technique study and work estimation by which any human work might be methodically analyzed in a request to assess and enhance the proficiency, straightforwardness, and economy with which it is performed (Dai 18). Technique ponders plans to enhance the way work is done and work estimation to build up the time required by a qualified laborer to convey out that work at a characterized level of execution. In the early years, the reliance of strategy and time was most certainly not for the most part acknowledged by the individuals who contemplated work keeping in mind
ISO 9000-1 addresses quality management and quality assurance standards. This document defines the primary concept of the series such as principal objectives and responsibilities, the process of an organization, and the roles of documentation. This document also provides a definition of terminology and provides guidance needed for all ISO 9000 series issues.
As these core standards include minimum wages, a clean working environment, monitoring of supervisor behavior and setting up of committees to address workers grievances etc.
Standardization can be described as an economy of productivity, where prices and quantities are the most important elements. The focus is to increase the productivity, which will help in
Owen (Owen, Dec 1986) of Lankro Chemicals provides four reasons why their company implemented Quality System Standard. They are to: (1) reduce failure (2) reduce the costs of customer claims (3) get things right the first time (4) improve service to the customer and to increase competitiveness.
In regards to the quality of supervision, which is one of the five facets of job
All work must be highly specified as to content, sequence, timing and outcome. If the work is not specified in detail, a considerable variation in how the employees do their work will occur. This variation will translate into poorer quality, lower productivity and higher costs. Most important, it will hinder learning and improvement in the organization because the variation hides the link between how the work is done and the results (Spear and Bowen, 1999). Standardizing processes within the utility will allow all participants to understand what needs to be done. IAM has already touched this by proposing the PDCA-methodology. However, systems are becoming more and more complex, clear indicators and objectives must be defined and be understandable by everyone (Granger et al., 2010) . Standardizing routines like CCTV reports, inspections as well as bigger tasks like the development of a strategic plan will make it possible to improve them and achieve a better quality of asset
Toyota is also the birth of kaizen. Toyota company tries to persistently enhance their standard procedures and strategies keeping in mind the end goal to guarantee most extreme quality, enhance effectiveness and dispose of waste. This is known as kaizen and is connected to each part of the organization's activities. Kaizen is the heart of the Toyota Production System. Like all large scale manufacturing frameworks, the Toyota process requires that all tasks, both human and mechanical, be decisively characterized and institutionalized to guarantee most extreme quality, dispose of waste and enhance effectiveness. Toyota Members have an obligation not just to take after nearly these institutionalized work rules additionally to look for their constant change. The everyday changes that Members and their Team Leaders make to their working practices and gear are known as kaizen. The term likewise has a more extensive meaning: it implies a constant making progress toward change in each circle of the Company's exercises - from the most essential assembling procedure to serving the client and the overall