3 Sheets of Standardized Work
January 4, 2016
There are 3 Sheets in standardized work :
1) Standardized work chart (SWC)
2) Standardized work combination table (SWCT)
3) Production capacity sheet (PCS)
Those 3 sheets is interlinked, when we will improve standardized work, so we must make 3 sheets to evaluate current condition before we make improvement.
Standardized Work Chart
“The standardized work chart shows operator movement and material location in relation to the machine and overall process layout. It should show takt time, work sequence, and standard WIP.
The standardized work chart is one of the three basic forms for creating standardized work, along with the standardized work combination table and job instruction sheet. The purpose of standardized work, according to Kaizen Express from which this form is taken, is to provide a basis for continuous improvement through kaizen.”
On standardized work chart we can view and evaluate
- Operator’s movement
- Machine’s layout
- Standard in process stock
- Safety precaution
- Quality check
- Cycle time
- Takt time
- Number of operator
SWC must be linked to SWCT, it is mean movement in SWC same with movement in SWCT so we can evaluate easily.
Standardized Work Combination Table (SWCT)
“The standardized work combination table shows the combination of manual work time, walk time, and machine processing time for each operation in a production sequence. This form is a more precise process design tool than the Operator Balance Chart. It can be very helpful to identify the waste of waiting and overburden, and to confirm standard work―in―process.
The standardized work combination table is one of three basic forms for creating standardized work, along with the standardized work chart and job instruction sheet. The purpose of standardized work, according to Kaizen Express from which this form is taken, is to provide a basis for continuous improvement through kaizen.”
1 sheet of SWCT is for 1 operator
On SWCT we can evaluate detail time of operator movements and we can see there’s waiting time if Machine Cycle Time bottleneck > Net Cycle Time of operator
Picture above is how to draw SWCT chart,
– Vertical line in the end is Cycle Time of the operation
– Vertical red line is Takt Time
– Red arrow is waiting time
– Curve is walk
– Solid line is time for each work name
If you want to draw SWCT automatically please go to download page to download SWCT template for auto generator.
Production Capacity Sheet (PCS)
Production Capacity Sheet is used to calculate the capacity of each machine in a production line to confirm maximum capacity and to identify and eliminate bottlenecks.
Processing capacity per shift will be calculated from the available production time, completion time, and tool-change time (and other factors as necessary) for each work piece.
Basic calculation for each machine is
- Basic Time (we called MCT = Machine Cycle Time)
MCT = HW + MT
MT = Machine Time, Auto operation from switch on until finish
- Tool Change
Change = Qty for change tool (tool’s life time) (pcs)
Time taken = Time for change tool (second)
Tool change unit is sec/pc
- Processing Capacity
Processing Capacity = Working Time / (MCT+Tool Change)
Purpose of Production Capcaity Sheet
- Evaluate the maximum capacity that can be produced for each machine in the production line
- The bottle neck machine (less capacity),
- Line capacity is the bottle neck machine capacity