Standardised Work: Creating Workpackages

The 2 Routes to Workpackage Implementation

Identify Work

Sequence

Identify Categories

of Work

Calculate

Takt Time

Apply To Current State

Line Balance

Align To

Programme Plan

Line Balance Board

Creation

PerformanceManagement

Workpackages in Place?

No Yes

Com

mon

Ste

ps

Route A

Workpackages Not In Place

Implementation Involves:

-Data analysis & capture

-Line balance creation

-Calculation of Takt Time

-Balancing to Takt

-Alignment to Programme Plan

-Inclusion into Performance Management System

Use when:

-There’s a requirement to match pace of production to customer demand

-Trying to create man/material flow

Route ARoute B

Workpackages In Place

Implementation involves:

-Calculation of Takt Time

-Rebalancing to suit new Takt

-Re-alignment to Programme Plan

-Inclusion into Performance Management System

Use when updating Workpackages:

- Rate change

-Level of resource change

-Removal of Waste/Reduction of NVA

Route B

Critical to WkPkgs

Discipline ‘C’

Critical to WkPkgs

Discipline ‘B’

Build, Time, Support, Other…

Discipline ‘A’

Route A: Identify Work Sequence & Categories of Work

1. Map the current operational processes

- Identify ‘who does what & when’ (Tasks & Times)

- Identify Critical Build Sequence

- Identify the categories of work -Value Added, Non-Value Added & Waste Activities

2. Collect issues with current processes

- Build (Sequence of, process interference etc)

- Time (questioning the current package allowance etc)

- Support (Engineering, Quality, Support, Operations etc)

- Other (anything else...)

- Create Tactical Implementation Plans to resolve issues

Route A: Line Balance Board Creation

1. Transfer operational processes onto strips

- Opportunity to discuss & resolve ‘Build’ issues

- Use Coloured magnets/paper strips to show the categories of work (VA, NVA, Waste)

Route A/B: Calculate Takt Time

Takt = Total Time Available* (* minus agreed losses – Time Total Customer Demand lunch, breaks etc)

1. Calculate the ‘drumbeat’ for production

- Calculate the frequency at which the production system must produce quality product

- In the above example, a Unit must be produced every 25 hours to satisfy the requirement of 12 Units/Month

Example:

Takt = 300 Hours/Month* (* minus agreed losses – Time 12 Units/Month lunch, breaks etc)

= 25 Hours

Operators

Tim

e

Operators

Tim

e Takt Time

Route A/B: Apply Takt Time to Current State Line Balance

Re-Balance

1. Rebalance processes to suit Takt Time- Maintain critical build sequence & re-balance ‘floating’ tasks

- Identify manning & capacity requirements to work to Takt Time

Operators

Tim

e Takt Time

WP1

WP4

WP2

WP5

WP3

WP6

2. Create Workpackage documentation- Create workpackage documentation according to team/workstation requirements

- Agree a suitable management time frame for updating of status (i.e. 1 hour, 1 shift etc)

Route A/B: Align to Programme Plan

Date

Day FRI W/E FRI W/E

Shifts E L N E L N E L N E L N E L OT E L N E L N E L N E L N E L OT E L

Programme Start 625 627 629MSN625 MSN627 MSN629

FUEL Stbd F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F1 F2 F3 F4 F5 F6 F7 F8TRAIL / LEAD TL1 TL2 TL3 TL4 TL5 TL6 TL7 TL8 TL9 TL10 TL11 TL12 TL1 TL2 TL3 TL4 TL5 TL6 TL7 TL8 TL9 TL10 TL11 TL12 TL1 TL2 TL3 TL4 TL5 TL6 TL7 TL8

MSN625 MSN627 MSN629FUEL Port F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F1 F2 F3 F4 F5TRAIL / LEAD TL1 TL2 TL3 TL4 TL5 TL6 TL7 TL8 TL9 TL10 TL11 TL12 TL1 TL2 TL3 TL4 TL5 TL6 TL7 TL8 TL9 TL10 TL11 TL12 TL1 TL2 TL3 TL4 TL5

MSN625 MSN627FUEL Stbd F13 F14 F15 F16 F17 F18 F19 F20 F21 F22 F23 F24 F13 F14 F15 F16 F17 F18 F19 F20TRAIL / LEAD TL13 TL14 TL15 TL16 TL17 TL18 TL19 TL20 TL21 TL22 TL23 TL24 TL13 TL14 TL15 TL16 TL17 TL18 TL19 TL20

MSN625 MSN627FUEL Port F13 F14 F15 F16 F17 F18 F19 F20 F21 F22 F23 F24 F13 F14 F15 F16 F17TRAIL / LEAD TL13 TL14 TL15 TL16 TL17 TL18 TL19 TL20 TL21 TL22 TL23 TL24 TL13 TL14 TL15 TL16 TL17

Programme EndMSN625

FUEL Stbd B B B B B B B BTRAIL / LEAD B B B B B B B B

MSN625FUEL Port B B B B BTRAIL / LEAD B B B B B

PAINT Stbd

PAINT Port

Number of Work packages 2 2 2 4 4 4 4 4 4 4 4 4 6 6 6 8 8 8 8 8 8 8 8 8 10 10 10 12 12 12 12 12am pm ns am pm ns am pm ns am pm ns am pm OT am pm ns am pm ns am pm ns am pm ns am pm OT am pm

FUEL REQ'D 6 6 2 12 12 4 12 12 5 12 12 5 18 18 6 24 23 7 23 22 7 21 22 6 22 23 6 24 23 7 23 22FORECAST 26.8 27.7 6.7 26.8 27.7 6.7 26.8 27.7 6.7 26.8 27.7 6.7 26.8 27.7 0.4 26.8 27.7 6.7 26.8 27.7 6.7 26.8 27.7 6.7 26.8 27.7 6.7 26.8 27.7 1.3 26.8 27.7VARIANCE 21 22 5 15 16 3 15 16 2 15 16 2 9 10 -6 3 5 0 4 6 0 6 6 1 5 5 1 3 5 -6 4 6MAN HOURS REQ'D 42 42 14 84 84 28 84 84 35 84 84 35 126 126 42 168 161 49 161 154 49 147 154 42 154 161 42 168 161 49 161 154

TRAIL / LEAD REQ'D 6 7 13 14 14 14 14 14 19 21 25 28 1 26 28 1 24 25 23 25 25 28 1 26 28FORECAST 25.2 26.8 25.2 26.8 25.2 26.8 25.2 26.8 25.2 26.8 25.2 26.8 25.2 26.8 25.2 26.8 25.2 26.8 25.2 26.8 25.2 26.8VARIANCE 19 20 12 13 11 13 11 13 6 6 0 -1 -1 -1 -1 -1 1 2 2 2 0 -1 -1 -1 -1MAN HOURS REQ'D 42 49 91 98 98 98 98 98 133 147 175 196 7 182 196 7 168 175 161 175 175 196 7 182 196CUMULATIVE VARIANCE 40 42 5 27 29 3 26 29 2 26 29 2 15 16 -6 3 4 -1 3 5 -1 7 8 1 7 7 1 3 4 -7 3 5

am pm ns am pm ns am pm ns am pm ns am pm OT R B G R B G R B G R B G R B OT R BFUEL 32 33 8 32 33 8 32 33 8 32 33 8 32 33 1 32 33 8 32 33 8 32 33 8 32 33 8 32 33 2 32 33

TRAIL / LEAD 30 32 30 32 30 32 30 32 30 32 30 32 30 32 30 32 30 32 30 32 30 32

Sickness % 3% 3% 3% 3% 3% 3% 3% 3% 3% 3% 3% 3% 3% 3% 3% 3% 3% 3% 3% 3% 3% 3% 3% 3% 3% 3% 3% 3% 3% 3% 3% 3%Diversion % 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% 9%

Holiday % 5% 5% 5% 5% 5% 5% 5% 5% 5% 5% 5% 5% 5% 5% 5% 5% 5% 5% 5% 5% 5% 5% 5% 5% 5% 5% 5% 5% 5% 5% 5% 5%

PAINT

19-Mar 22-Mar15-Mar 16-Mar 17-Mar 18-Mar

13

MON

12

MON TUE WED THUR MON TUE WED THUR

8-Mar

BAY1

BAY2

BAY3

11

9-Mar 10-Mar 11-Mar 12-Mar

Date

Workpackages

Workstations

Manning Levels

1. Create high-level Workpackage Schedule document

- Visually represent where & when each Workpackage is scheduled to be completed

- Shows level of resource required when working to Takt Time

TEAM BOARD : STATION 99QUALITY COST DELIVERY PEOPLE

SCRAP

CONCESSIONS / DEFECTS

PRODUCTIVITY SKILLS MATRIX

ATTENDANCE

HEALTH & SAFETY

TAKT ADHERENCE

5C

CURRENT

PREVIOUS

LOCAL INFORMATION

DISRUPTIONS

SHIFT : TEAM LEADER :

SIGN OFF

PRD File

ISSUES RESOLVED

Route A/B: Performance Management

1. Display Workpackage documentation at the place of work

- Increase Visual Management at the workstation

- Process ownership clear with key stakeholders involved

- Workpackage Status to be updated at the agreed management time frame interval

- Issues regarding workpackage adherence to be raised, resolved & escalated if necessary from this location

Route A/B: Workpackages Created

Identify Work

Sequence

Identify Categories

of Work

Calculate

Takt Time

Apply To Current State

Line Balance

Align To

Programme Plan

Line Balance Board

Creation

PerformanceManagement

Workpackages in Place?

No Yes