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TWI and Standard Work
www.TWI-Institute.org
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Standardized Work vs.
Work Standards
Work Standards Definitions*:
Quality, Safety and Environmental StandardsFit and Finish – Not detailed in Standardized Work
Established to follow state and federal regulations may be identified as the safety cross.
Standard SpecificationsTechnical Information– Not detailed in Standardized Work
Corrective Action information – typically handled outside the Standardized Work for the operator
Standard Procedures
Standards should be visually defined and self explanatory– Not detailed in Standardized Work
*The Toyota Way Fieldbook, p 118-122 Liker & Meier, 2006
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Standardized Work
graphical structure best utilized for situations with multiple
operators or an automatic machine cycle
begins life as and
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STANDARDIZED WORKCHART
PROCESS Cycle Time TAKT TimeSAFETY QUALITY IN PROCESS
Gl ost Ki ln Op era tor Cycl e 3 0-m in ute s 1-cycl e / 90-
minutes
Element
Number
Description Work Time Walk
TimeWORK AREA LAYOUT
1 Walkto GK #3 Exit 1.0
2 Discharge Car from GK#3 5.0
3 Discharge Car from GK#4 5.0 1.2
4 Record GK#4 car numbersan d
temps1.0 0.7
5 Charge GK#4 5.0 0.3
6 Charge GK#3 5.0 1.0
7 Record GK#3 car numbersan d
temps1.0 0.6
8 Return to loading 0.6
Total (min): 22 5.4COMMENTS:
S af et y: Use h ig h t em p g lo ve s, pu sh er t o m ove ca rs a nd be mi nd fu l f or oi l y/ sl ic ksu rf ac esQ ua li t y: I nsp ec t ki l n ca rs a n d rep ai r d owne d ware an d ref ra ct ory. Use c are no t t o da ma ge glaz e o f u nf ired wa re
GK#4
GK#3
ENTRANCE
ENTRANCE
EXIT
EXIT
1, 8
2
3
4
5
6
7
Panel Board
Panel Board
Load Station
Load Station
Standardized Work
combined sheets best usedwith single operator and no
automatic cycle
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How do you teach operators to do the
Standardized Work Elements?
• TWI implements Job Instruction with the
proven 4 step methodology.
• Traditional Lean Implementations deliver
‘Standard Work’ forms and rely on a variety of
work standards to teach the operators.
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TPS/TWI Job Instruction(how to do/teach the job)
Job Instruction Breakdown
JOB INSTRUCTION BREAKDOWNElement Description:Charge GK #4
SAFETY QUALITY IN PROCESS
Element Number: 5 PARTS:Tools and Materials:High Temp Gloves
# IMPORTANT STEPS KEY POINTS REASONS ILLUSTRATIONS
A logical segment of the operation whensomething happens to advance the work.
Anything ina step that might—
1.Makeor break thejob2.Injurethe worker3.Makethe work easier to do
(“knack”, “trick”, special timing,bit of special information)
Reasons for Key Points
1Open doors
1. Use high temp gloves2. Turn clockwise3. Swing past floor pit
1. Very hot2. Opens in reverse3. Car will wreck
2 Move t rans fer over 1. Lat ch dogs down 1. Mak es t rans fer eas ier
3 Push car onto transfer1. Move slowly2. Fix downed ware / refractory
1. Ware quality2. Ware quality
4Push transfer back intokiln
1. Ensure dog is latched1. Car will not push intokiln
5 Close doors
1. Use high temp gloves2. Turn counterclockwise
1. Very hot2. Closes reverse
6 Check hydraulic pressure1. Needle in green ofgauge
1. Ensures hydraulicpressure to push
7
8
9
10
NOTES:Safety: wear hard hat when moving kiln cars. Notify supervisors if car quality is in question (structurally)
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TWI LEAN EXAMPLE-Ceramic Kiln Operator
• Operators struggling to keep up with process.Ergonomic issues noted.
• Union-Management Improvement team
assembled to investigate.• There is a high level of variation between
operators and shifts
• An excessive amount of walking was noted.
• Operators were not conducting routineprocess controls
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Stabilization
• Included others indeveloping Job Instruction
• Train all operators to oneprocedure
• Refocus on quality at thesource versus just keepingup
• Reduce noise by eliminatingvariation
No. __________
JOB INSTRUCTION BREAKDOWN SHEET
Operation: Glost Kiln Operator Cycle _
Parts: None _
Tools & Materials: Kiln Gloves _
IMPORTANT STEPS KEY POINTS REASONS
A logical segment of the operation when
something happensto advance the work.
Anything in a step that might—
1.Make or break the job2.Injure the worker
3.Make the work easier to do, i.e. “knack”,“trick”, special timi ng, bit of special
information
Reasons for the key points
1. Discharge GK #3 1. Use kiln gloves2. Pull at correct time
1. Burn hazard2. Kiln control
2. Charge GK #31. Fix downed ware2. Do not slam transfer
1. Defect prevention2. Defect prevention
3. Record car data
4. Check kilntemperatures
1. Call Ceramic Tech if50°F delta in zones
1. Proper kiln control
5. Charge GK #3
1. Fix downed ware
2. Do not slam transfer
1. Defect prevention
2. Defect prevention
6. Discharge GK #31. Use kiln gloves2. Pull at correct time
1. Burn hazard2. Kiln control
7. Record car data
8. Check kilntemperatures
1. Call Ceramic Tech if50°F delta in zones
1. Proper kiln control
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Identify Improvements(JM Breakdown)PRODUCT: Glost Ware MADE BY: Lanno DATE:
OPERATIONS: Glost Kiln Operator DEPARTMENT: Lean Team
CURRENT/PROPOSEDMETHOD DETAILS
D i s t a n c e
t r a v e l e d
i n f e e t
REMARKS
W H Y -
W H E R E
W H E N
W H O
H O W
IDEAS
E l i m i n a t e
C o m b i n e
R e a r r a n g
S i m p l i f y
TIME/TOLERANCE/
REJECTS/SAFETYWrite them down, don’t try to remember.
1 Discharge GK #4 x
2 Walk to control panel 148 45 x Eliminate special trip to record this data point x
3 Record car number x xCan bar codes be used to eliminate this manualstep?
x
4 Walk to control panel 145 40 x Eliminate trips to control panels (back tracking) x
5 Check kiln readings x xCan kiln check be put on a 90-minute check asroutine?
x
6 Walk to GK #4 loading 137 35 x Eliminate trips to control panels (back tracking) x
7 Load car
8 Walk to GK #4 entrance 135 35 x x Item #5 x
9 Charge ki ln
10 Walk to control panel 41 15 x Item #6
11 Record car number
12 Walk to GK #3 242 60 x x x
13 Discharge car
14 Walk to control panel 138 45 x Item #6
15 Record number x x Item #3 x
16 Walk to GK #4 137 35
17 Load car
18 Walk to GK #3 236 60
19 Charge kiln
20 Walk to control panel 99 25 x Item #6 x
21 Record data
22 Kiln check x x
23 Walk to control panel 145 60 x Item #6 x
24 Record kiln data x Install ANDONs to eliminate 90-minute kiln checks x
25 … … …
2024-ft 555-seconds (travel only) 10
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Improvements Into Action
• Andon installed on kilns to alarm whentemperature deltas were poorly impacting the kiln
profile
• Worked with Planning on procedure to change kilncycle, therefore walk patterns were minimized
• Focus on kiln car condition and repair with time
savings. Direct correlation to first pass yield
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Kiln Operator Example (SW Chart)STANDARDIZED WORKCHART
PROCESS Cycle Time TAKT TimeSAFETY QUALITY IN PROCESS
Glost Kiln Operator Cycle 30-minutes 1-cycle / 90-minutes
ElementNumber
Description Work Time WalkTime
WORK AREA LAYOUT
1 Walk to GK #3 Exit 1.0
2 Discharge Car from GK#3 5.0
3 Discharge Car from GK#4 5.0 1.2
4 Record GK#4 car numbers
and temps
1.0 0.7
5 Charge GK#4 5.0 0.3
6 Charge GK#3 5.0 1.0
7 Record GK#3 car numbers
and temps1.0 0.6
8 Return to loading 0.6
Total (min): 22 5.4COMMENTS:
Safety: Use high temp gloves, pusher to move cars and be mindful for oily/slick surfacesQuality: Inspect kiln cars and repair downed ware and refractory. Use care not to damage glaze of unfired ware
GK#4
GK#3
ENTRANCE
ENTRANCE
EXIT
EXIT
1, 8
2
3
4
5
6
7
Panel Board
Panel Board
Load Station
Load Station
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Kiln Operator Example (Element JI)JOB INSTRUCTION BREAKDOWN
Element Description:
Charge GK #4
SAFETY QUALITY IN PROCESS
Element Number: 5 PARTS:Tools and Materials:High Temp Gloves
# IMPORTANT STEPS KEY POINTS REASONS ILLUSTRATIONS
A logical segment of the operation whensomething happens to advance the work.
Anything in a step that might—1.Make or break the job2.Injure the worker3.Make the work easier to do
(“knack”, “trick”, special timing,bit of s pecial information)
Reasons for Key Points
1 Open doors1. Use high temp gloves
2. Turn clockwise3. Swing past floor pit
1. Very hot
2. Opens in reverse3. Car will wreck
2 Move transfer over 1. Latch dogs down 1. Makes transfer easier
3 Push car onto transfer
1. Move slowly
2. Fix downed ware / refractory
1. Ware quality
2. Ware quality
4 Push transfer back into kiln 1. Ensure dog is latched 1. Car will not push into kiln
5 Close doors1. Use high temp gloves2. Turn counter clockwise
1. Very hot2. Closes reverse
6 Check hydraulic p ressure 1. Needle in green ofgauge
1. Ensures hydraulicpressure to push
7
8
9
10
NOTES:Safety: wear hard hat when moving kiln cars. Notify supervisors if car quality is in question (structurally)
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Kiln Operator Example (Impact)
Before After Savings Reduced%
Distance
Walked
per Shift
16,192-ft 5,745-ft 10,447-ft 65%
2.8-miles 1.0-mile 1.8-miles 65%Time
Walking
per shift
73-min 27-min 46-min 63%
Time saved allowed Kiln Operators to repair kiln cars
resulting in higher First Pass Yields
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TWI/Lean Integration
• Stabilize your work method
– Use Job Instruction and Standardized Work
• Evaluate and improve your work method
– Use Job Methods with Lean techniques
• Stabilize your improved work method – Use Job Instruction and Standardized Work
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