Standardization and 5S Lecture

Question 1

Standardization

Answer 1

• standardized work origin
• standardized work process
• standardized operational requirements
• standardized facility - 5S
• standardized management work
• standardized thinking

Question 2

standardized work has 2 purposes:

Answer 2

• it clarifies rules of the production method

- it is the basis for kaizen (continuous improvement)

Question 3

3 elements of a manufacturing cell

Answer 3

• sequence of operations
• cycle time
• stock on hand

Question 4

definition of standardized work

Answer 4

a document centered upon human motion that combines the elements of a job into the most effective sequence with minimal waste to achieve the most efficient level of production possible under current conditions

Question 5

actual standardized work in TPS - 3 requirements (stability)

Answer 5

• repetitive cyclical work
• high process and part quality
• low equipment downtime

Question 6

actual standardized work in TPS - 3 elements

Answer 6

• takt time
• work sequence
• standard work in process

Question 7

actual standardized work in TPS - 3 forms

Answer 7

• process capacity sheet
• standardized work combination sheet
• standardize work chart

Question 8

process capacity sheet

Answer 8

• the maximum capacity for part processing at any one process
• record the amount of time spent in manual work and the machines automatic operation time
• the time spent in “changing cutting tools” “set-up time”

Question 9

standard work combination sheet

Answer 9

these go hand-in-hand with standard work sheets. in essence, the standard work combination sheet shows work flow on a graph and clearly depicts: walking, waiting, machine time, operation cycle time

Question 10

any company with an obsessive drive to eliminate waste and create perfect order, must have…

Answer 10

clear definition of current state in all aspects of business. this current state definition is: the standardization of:

• direct labor work processes
• indirect labor work processes
• salary work processes
• facilities (visual management / 5S)

Question 11

Standards properly implemented, documented and led, will clearly demonstrate

Answer 11

DEVIATION to the standard when it occurs requiring immediate correction. continuous improvement / Kaizen infrastructure assures resolution.

Question 12

when problem solving defects, there must be

Answer 12

an assurance that the standard work is being followed. there is no time to investigate how the work was completed. the assurance of standard work minimizes the variation related to workmanship

Question 13

what is 5S?

Answer 13

• a method to standardize the facility beyond the workstation to allow the organization to quickly spot deviation for immediate corrective action
• Seiri, Seiton, Seiso, Seiketso, Shitsuke - Sort, Set in order, Shine, Standardize, Sustain

Question 14

5S is NOT

Answer 14

a housekeeping system to ensure cleanliness, although it accomplishes this objective as a side benefit

Question 15

how to implement 5S

Answer 15

• assemble the team
• define the area
• train and explain how and the why of 5S
• Sort - begin tagging process
• Set in order
• Shine
• Standardize
• Sustain
• Lead by example and teach the system

Question 16

Sort - begin tagging process

Answer 16

• red tag: those items that need permanently removed
• yellow tag: those items that are used periodically by the operation
• green tag: those items used every cycle

Question 17

Set in order

Answer 17

define a place for everything, footprint, label, shadow board, etc. to assure everything has a place. begin displaying metrics in each work area to assure visual and immediate understanding of deviation from standards

Question 18

Shine

Answer 18

sanitize the work area and equipment

Question 19

Standardize

Answer 19

document the rules and procedures to ensure compliance and understanding of all documented methods of control

Question 20

Sustain

Answer 20

compliance must be a part of team goals by incorporating measurable conformance to standards. develop a scheduled, documented plan for daily, weekly, monthly, and annual maintenance of the system with assigned responsibility

Question 21

Sustain: escalation standard

Answer 21

• 0 hours product stopped - call responsible party
• 1/2 hour with product stopped - text first level escalation with message for the appropriate escalation group
• 1 hour with product stopped - text page second level escalation
• 1.5 hours with product stopped - text page third level escalation
• 2 hours with product stopped - text page fourth and final level of escalation

Question 22

Andon is an extension of

Answer 22

Autonomation/Jidoka

Question 23

Autonomation/Jidoka is providing the machine

Answer 23

a “human touch” - the machine has logic to identify deviation and stop

Question 24

Andon does what?

Answer 24

simulates this machine function by creating a system in which the team member indicates a deviation requiring team response in a pre-defined, standardized way

Question 25

implementing Andon

Answer 25

- think of team member as the automated machine. the same efford of building the human touch into the automation for deviation must be done for the team member - operator must have means of signaling a need for help - the response should be defined around the capability to respond to the current system - as process improves via 5 why corrective action and/or other problem solving techniques, the andon procedure is tightened for greater response, standardized, trained and implemented

Question 26

Fishbone diagram for poor standardization

Answer 26

4 groups: process, people, materials, training