Standardization and 5S Lecture Flashcards Preview

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Flashcards in Standardization and 5S Lecture Deck (26):


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


standardized work has 2 purposes:

- it clarifies rules of the production method
- it is the basis for kaizen (continuous improvement)


3 elements of a manufacturing cell

- sequence of operations
- cycle time
- stock on hand


definition of standardized work

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


actual standardized work in TPS - 3 requirements (stability)

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


actual standardized work in TPS - 3 elements

- takt time
- work sequence
- standard work in process


actual standardized work in TPS - 3 forms

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


process capacity sheet

- 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"


standard work combination sheet

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


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

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)


Standards properly implemented, documented and led, will clearly demonstrate

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


when problem solving defects, there must be

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


what is 5S?

- 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


5S is NOT

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


how to implement 5S

- 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


Sort - begin tagging process

- 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


Set in order

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



sanitize the work area and equipment



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



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


Sustain: escalation standard

- 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


Andon is an extension of



Autonomation/Jidoka is providing the machine

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


Andon does what?

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


implementing Andon

- 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


Fishbone diagram for poor standardization

4 groups: process, people, materials, training