Standard Work

Standard Work

One of the most important but least often used tools of lean manufacturing is Standardized Work^(1,2). Quite simply, the principles of lean and flow production do not work well when everyone is allowed to choose the method or sequence in which to do the job; quality suffers, and productivity drops⁽¹⁾.

(download sample Work Instruction )

Standardized work is a detailed, documented and visual system by which associates develop and follow a series of predefined process steps. An important part are the Standardized Work Instructions which represent the current best practices for workers to follow in the completion of their jobs. They are designed to minimize process variation introduced by the worker. This reduces waste, eases problem solving and enhances productivity within a particular job or set of jobs⁽¹⁾. Visual Work Instructions, provide a convenient way for supervisors to check the operators’ actions and add discipline to the culture⁽³⁾.

The benefits of incorporating standardized work are numerous and include:

• Capture of employee knowledge so that it becomes a corporate asset;
• Enhanced productivity;⁽³⁾
• Maintenance and improvement of quality;⁽⁴⁾
• Reductions in waste;⁽³⁾
• Reductions in cost;⁽⁴⁾
• Reductions in variability;⁽²⁾
• Easier training of new operators;⁽²⁾
• Reductions in injuries and strain;⁽²⁾ and
• Provision of a baseline for improvement activities.⁽⁴⁾

 People are creatures of habit and masters of adaptation.⁽⁶⁾  While adapting operators develop ‘best practices’ that are used to make production more efficient and hopefully easier. Standardized Work ensures that these ‘best practices’ are not lost over time and are available to set the standard for all employees (new and old) to live by.⁽⁵⁾ In short, Standardized Work Instructions provide corporate memory of best practices.⁽³⁾

The key to Standardized Work is not having a document saying this is what the standard process is; the key is having a document that is actually used. For that reason it is essential that the work instructions are easy to use (visible and as simple as possible) and easy to update (to avoid the common problem of the process changing and the work instructions losing touch with what is actually done). ⁽⁵⁾

 If you are thinking about getting started with  Standardized Work or are struggling with your current method of controlling your  Standardized Work documents, we would welcome the opportunity to talk with you about how either LockStep or Sequence Enterprise can greatly reduce the time required for creation, revision management and deployment. To learn more, simply send us an email ( This e-mail address is being protected from spambots. You need JavaScript enabled to view it ) or fill out the request more information form and let us know how we can help.

References

1.  http://EzineArticles.com/?expert=Brian_Krichbaum

2. http://www.lean.org/workshops/WorkshopDescription.cfm?WorkshopId=20 ).

3.  http://wcm.nu/Lean/swi.html

4. http://management.curiouscatblog.net/2007/04/29/standardized-work-instructions/

5.  http://learnsigma.com/the-no-nonsense-guide-to-standardized-work/

6.  http://ezinearticles.com/?Corporate-Change---Human-Adaptability-and-Habit&id=3206012