6 1standard Work
6 1standard Work
Module 6.1
Jessica Dolak, LFM 06 Ben Lathrop, LFM 06 Kris Harper, LFM 02, Blinds To Go Rob Spina, MIT 99, Blinds To Go Presentation for: ESD.60 Lean/Six Sigma Systems MIT Leaders for Manufacturing Program (LFM) Summer 2004
These materials were developed as part of MIT's ESD.60 course on "Lean/Six Sigma Systems." In some cases, the materials were produced by the lead instructor, Joel Cutcher-Gershenfeld, and in some cases by student teams working with LFM alumni/ae. Where the materials were developed by student teams, additional inputs from the faculty and from the technical instructor, Chris Musso, are reflected in some of the text or in an appendix
Overview
Learning Objectives
Understand what is meant by standardized work Appreciate the value and limitations of standardized work See examples of standardized work results
Session Design (20-30 min.)
Part I: Introduction and Learning Objectives (1-2 min.) Part II: Key Concept or Principle Defined and Explained (3-5 min.) Part III: Exercise or Activity Based on Field Data that Illustrates the Concept or Principle (7-10 min.) Part IV: Common Disconnects, Relevant Measures of Success, and Potential Action Assignment(s) to Apply Lessons Learned (7-10 min.) Part V: Evaluation and Concluding Comments (2-3 min.)
Jessica Dolak & Ben Lathrop ESD.60 Lean/Six Sigma Systems, LFM, MIT
6/9/04 -- 2
Part I: Introduction
Part V: Conclusion
Definition
Standardized work is A TOOL FOR MAINTAINING PRODUCTIVITY, QUALITY, AND SAFETY, at high levels1 Standardized work is defined as work in which the sequence of job elements has been efficiently organized, and is repeatedly followed by a team member2 Standardized work is a process whose goal is kaizen. If standardized work doesnt change, we are regressing3
Source: 1) www.lean-biz.com/pdfs/standardize.pdf 2) Pascal Dennis, Lean Production Simplified (New York:Productivity Press, 2002)
Jessica Dolak & Ben Lathrop ESD.60 Lean/Six Sigma Systems, LFM, MIT
6/9/04 -- 3
Part I: Introduction
Part V: Conclusion
Source: Pascal Dennis, Lean Production Simplified (New York:Productivity Press, 2002)
Jessica Dolak & Ben Lathrop ESD.60 Lean/Six Sigma Systems, LFM, MIT
6/9/04 -- 4
Part I: Introduction
Part V: Conclusion
Work Sequence
The order in which the work is done in a given process Can be a powerful tool to define safety and ergonomic issues
In-Process Stock
Minimum number of unfinished work pieces required for the operator to complete the process
Source: Pascal Dennis, Lean Production Simplified (New York:Productivity Press, 2002)
Jessica Dolak & Ben Lathrop ESD.60 Lean/Six Sigma Systems, LFM, MIT
6/9/04 -- 5
Part I: Introduction
Part V: Conclusion
Jessica Dolak & Ben Lathrop ESD.60 Lean/Six Sigma Systems, LFM, MIT
6/9/04 -- 6
Part I: Introduction
Part V: Conclusion
Jessica Dolak & Ben Lathrop ESD.60 Lean/Six Sigma Systems, LFM, MIT
6/9/04 -- 7
Part I: Introduction
Part V: Conclusion
Blinds To Go Example
Standardization launched End Q1Y02 100%
95%
90%
85%
80%
75%
70%
65%
60%
55%
50% 2002 Q1 2002 Q2 2002 Q3 2002 Q4 2003 Q1 2003 Q2 2003 Q3 2003 Q4 2004 Q1
Jessica Dolak & Ben Lathrop ESD.60 Lean/Six Sigma Systems, LFM, MIT
6/9/04 -- 8
Part I: Introduction
Part V: Conclusion
Blinds To Go Example
99.00%
96.00%
95.00%
94.00%
93.00%
92.00%
91.00%
90.00% 2002 Q1 2002 Q2 2002 Q3 2002 Q4 2003 Q1 2003 Q2 2003 Q3 2003 Q4 2004 Q1
Jessica Dolak & Ben Lathrop ESD.60 Lean/Six Sigma Systems, LFM, MIT
6/9/04 -- 9
Part I: Introduction
Part V: Conclusion
Blinds To Go Example
50.00%
Standardization launched End Q1Y02
45.00% 40.00% 35.00% 30.00% 25.00% 20.00% 15.00% 10.00% 5.00% 0.00% 2000 2001 2002 YTD 2003
Part I: Introduction
Part V: Conclusion
Jessica Dolak & Ben Lathrop ESD.60 Lean/Six Sigma Systems, LFM, MIT
6/9/04 -- 11
Part I: Introduction
Part V: Conclusion
Concluding Comments
Standardized work is a method of defining efficient work process that are repeatedly followed by workers Standardized work often aims to maintain productivity, quality, and safety at high levels Improvement is endless and eternal
Toyota Proverb
Jessica Dolak & Ben Lathrop ESD.60 Lean/Six Sigma Systems, LFM, MIT
6/9/04 -- 12
Part I: Introduction
Part V: Conclusion
Time
2-3 min 5-8 min
Topic
Introduction, overview and learning objectives Key Concepts
Contrast SW with Taylorism and industrys recent separation of mental and physical labor (industrial engineers vs. line workers) Point out that the seven benefits listed on slide 4 are interwoven Stress that SW is a beneficial tool by itself but becomes even more powerful as part of a lean system
Source: Pascal Dennis, Lean Production Simplified (New York:Productivity Press, 2002)
Jessica Dolak & Ben Lathrop ESD.60 Lean/Six Sigma Systems, LFM, MIT
6/9/04 -- 14
Part I: Introduction
Part V: Conclusion
Time
7-10 min
Topic
Exercises/Activities/ Measurables
11 12
Source: Pascal Dennis, Lean Production Simplified (New York:Productivity Press, 2002)
Jessica Dolak & Ben Lathrop ESD.60 Lean/Six Sigma Systems, LFM, MIT
6/9/04 -- 15
Part I: Introduction
Part V: Conclusion