Tag: standard work document

Standard Work

Standard Work, what are the best practices to create them?

standard work is the base for improvements

Standard work documentation is important to record the right and only way to complete a process.  This document provides clear, simple, accurate, and complete information to support training.  Standard work is the foundation for improvements. If the foundation is weak, it will not drive the desired change.

Best Practices to create standard work documentation.

  • The people who do the work participates in the process
  • Include all relevant information on one easy-to-read document
  • Keep it simple and use visualization, if possible.
  • Make the documentation accessible
  • Set clear expectations regarding revisions and improvements

Components

There are different types of formats to document standard work.  Follow the best practices to create one that works for you and contains the three components of standard work.

  • Job sequence
  • The rate at which products must be produced to meet customer demand
  • Work-in-process inventory quantity

Types of Standard Work Documents

Standard Work DocumentationDescription
Process capacity sheetDefines the available capacity
Standardized combination tableDefines the work of one operator during the process cycle, it describes what the operator is doing and when it is doing it.
Standardized Work ChartIt is a simple layout of the work area that shows the flow of the worker, information, and materials through it while keeping the production rate to meet customer demand.
Work instructionA work instruction contains step by step information to do the work.  It has a combination of words and pictures or drawings to describe each step.  It also contains important tips for things that can make or break the job, safety, and quality.  
ChecklistThis simple document can have two different uses, to confirm that everything was done or to check as you carry out the task.
Visual aidSimple instructions using pictures or drawings to show the steps of the process.  They are posted at the point of use.
Memory joggerThese can be a group of laminated cards with general guidelines, settings, or other information that is not used very frequently.  

Importance of these documents

Create standard work documentation is important to record the safest, highest quality, and the most efficient way known to perform a task.  This document is the baseline for future improvements.  They reduce variation and improve consistency. 

Standard Work

Do you know the characteristics of standard work?

Standard Work (SW) is a simple written description of the safest, highest quality, and most efficient way to execute a particular task. Once established, it becomes the only acceptable way to do the process it describes.  Effective documentation and training are key to standard work success.  Use a template to ensure that all the standard work or work instructions look and contain the same parts or components.  

The three components 

  • Job sequence to complete the job
  • The rate at which products must be produced to meet customer demand (takt time)
  • The standard amount of work in process inventory

Relevant information to include with the job sequence   

  • Key points related to anything that can make or break the job
    • Information that addresses safety issues or risks
    • Instructions or knowledge that help performance such as, what makes the job easier or ensure quality.  
  • Explains why the step is important

Characteristics of effective work instructions

  • Simple and clear, easy to understand by everybody.  
  • Complete, it shows the steps to do the job and other relevant information. 
  • Accurate, the document reflects the current process.    
  • Concise, it contains important information only.

A work instruction is not effective, regardless of how good the document is if the training is not adequate.  If your idea of training is to bring a group of people to a room to read the work instruction, you should rethink the training method.  How effective do you think this type of training is?  How can you be sure that everybody understood the instructions?  

The work instruction by itself is not a training tool, it needs to be supported by other teaching methods.  To be effective, the instructor should tell and show how to do the job.  The following are some general guidelines. 

  • Demonstrate the job step by step while explaining the key points and why things are done a certain way.  
  • Repeat the steps as many times as you think it is necessary before asking the employee to try.
  • Observe the employee doing the job.
  • Ask to explain the key concepts and whys, make sure they understand.   
  • Follow-up on their performance, observe and correct if it is necessary.  
  • Create a safe and respectful environment.  
  • Make sure they know who to ask if they have doubts or find a problem.  
  • Check-in with the employee often, until you are completely sure that he/she understands the job.

Many organizations fail to implement standard work.  As a result, perceived gains through Kaizen may be lost over time, and the status quo prevails.  The standard work is not set in stone, it is the baseline for continuous improvement.  When the process change, the standard work is updated.

Standard work is important to ensure everybody follows the same guidelines, and the process is stable. That way, the customer will consistently receive their product or service on time, with the best quality, and at the lower possible cost.