Today, we’ll discuss how to write a Standardized Work Chart that enables you utilize Takt Time
in practice on an Excel template.
[Intro Video]
Hi, this is Mike Negami, Lean Sigma Black Belt.
I received this request on the video about Takt Time the other day.
“Can you make a Standardized Work template and introduce it?”
Thanks for your request.
Standardized Work is a method that Toyota established.
It consists of three elements: ‘Takt Time, Working Sequences, and Standard In-Process
Stock’, and is used in each workplace as the ‘Standardized Work Chart’.
Since this episode will be more detailed than the previous one, those who haven’t watched
the Takt Time video, please watch that video first.
Toyota has various famous tools and methods such as the ‘Kanban System’, ‘One Piece
Flow’, etc.
They cascade those effects to the frontlines with this ‘Standardized Work Chart’.
Furthermore, in order to create the ‘Standardized Work Chart’, it’s necessary to create
a ‘Standardized Combination Table’.
In order to create this ‘Standardized Combination Table’, it’s necessary to make a ‘Production
Capacity Sheet’.
We call these three sheets ‘the 3 tools of Standardized Work’.
I’ll explain each tool.
At Toyota, they first make a ‘Production Capacity Sheet’.
This is an example of that document.
It records current work procedures, actual manual work times, machine running times,
and numbers of each production in a certain time that are recorded with a stop watch.
This enables us to check the problem process that becomes a bottleneck.
Next, this is the ‘Standardized Combination Table’ that was created based on the ‘Production
Capacity Sheet’ and is written in further detail.
With this document, since you can visualize your manual work time, the machine running
time and the walking time of each step and compare it with its Takt Time, which is the
standard time, it becomes clear where and how much improvement should be made.
That way, you’ll reduce any walking waste and waiting waste of workers and machines,
and improve the target process to include the safest and most efficient procedures.
Lastly, make a ‘Standardized Work Chart’, which is today’s theme.
This is an example of the chart.
It describes the placement of equipment, the movement of people and the work procedures.
The Takt Time, Working Sequences and Standard In-Process Stock, which are the three elements
of Standardized Work should be included.
The last tool the ‘Standardized Work Chart’ is the most important.
Toyota reviews their production quantities every month, then they update the ‘Standardized
Work Chart’ every month as well.
Since they do that for all their workplaces, it must require great effort.
That’s how much Toyota values this ‘Standardized Work Chart’.
Their front-line supervisors are in charge of making and maintaining this document.
The key is that they patrol their sites and make sure all their workers follow the Standardized
Work thoroughly.
Furthermore, since they regularly revise the ‘Standardized Work Chart’, their Standardized
Work will be improved each time.
They’re doing this company-wide.
Toyota is a really special company.
If you can make a ‘Standardized Work Chart’ by analyzing with the ‘Production Capacity
Sheet’ and ‘Standardized Combination Table’ as I mentioned, the improvement would be very
big.
However, the bar is a little bit too high for us to do all those tools on our own, so
I only made the template of ‘Standardized Work Chart’ this time and will introduce
another way to complete the document.
I made a template in the past that can measure cycle time.
Since you can complete production leveling, which is Heijunka with that template, you
can analyze and improve your process.
After that, it’s a good idea to record the improved process in the ‘Standardized Work
Chart’ template.
This is the Standardized Work Chart template.
The instructions are written on the right side.
First, fill out each step of the improved process in this left column.
Be aware that each step has a step number.
Next, copy and paste this equipment icon and arrange your equipment locations.
You may want to label each piece of equipment on the icons.
You can copy them easily by dragging the shape while pressing down your control key.
Next, arrange the step numbers according to the movement of the workers.
Then connect them with solid arrows in order of step number.
Use a dashed arrow to connect the final number and Step 1.
Here are three special symbols.
Use this diamond symbol to clarify steps where a quality check is necessary.
Use this cross symbol where special safety attention is needed and use the black circle
symbol where you keep Standard In-Process Stock.
This is the completion of the Working Sequences, which is one of the three elements of Standardized
Work.
Lastly, please fill in the other 2 elements, the number of Standard In-Process Stock and
Takt Time, below.
This method was developed by Toyota.
It might be difficult to do thoroughly the way they do, but let's try to at least make
the Standardized Work Chart.
That will be the first step towards improvement.
“There is no improvement without standards.”
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