Think of standardized work as the operating system behind every efficient production line. It lists the raw materials, assigns roles, documents the process steps, and tells you what to expect at the end. This is one of the fundamental principles of lean manufacturing and the Toyota Production System (TPS).
In this article, we dive into what standardized work is, how it supports lean manufacturing, and share practical tips for implementing and digitizing it.
What Is Standardized Work?
Standardized work refers to documenting the most efficient and effective way to perform a task or a series of tasks. This can take the form of:
- Written work instructions
- Standard Operating Procedures (SOPs)
- Instructional videos
- 8 Step Processes
- 1 Point Lessons
- TWI job instructions
Standardized work must involve 3 key elements:
- Takt Time
This is the time required to manufacture a unit and meet the delivery deadline. Takt time is not the same as lead time. While lead time refers to the entire time between order placement and order fulfillment, takt time refers only to the actual production time.
- Work Sequence
This is the precise sequence of steps to be performed to manufacture a single product.
- Standard Inventory/ Standard Work-in-Process
This is the amount of raw material required at every stage to keep the process operating smoothly.
It is important to note that standardized work is not a static concept. Instead, this forms the foundation for Kaizen or continuous improvement. When a better way to complete a task is identified, standardized work processes can be updated to improve efficiency.
How Standardized Work Supports Key Lean Principles
Standardized work is key to maintaining a steady output with consistent quality, waste reduction, and continuous improvement. Here’s how.
Higher Efficiency
Standardized work ensures that all employees follow the same sequence of steps to get a task done in the same amount of time. There’s less variation in output and delivery timelines become easier to meet. It also makes it easier to spot opportunities to streamline the process even further.
Waste Reduction
Standardization is instrumental in removing the 8 wastes of lean manufacturing.
First, it reduces the risk of defects and helps ensure that all products and services meet expected quality standards. It also prevents overproduction and waste related to holding excess inventory.
By cutting down on non-value-added processes and optimizing processes, standardization helps organizations make better use of available resources. In addition, it can also cut down on idle time, transportation, and unnecessary movement of resources. Thus, it helps build a leaner, cost-effective operating system.
Greater Visibility
Having a detailed document laying out the steps to be followed allows managers to observe, monitor, and measure operational processes. It also facilitates an easier transfer of knowledge when onboarding and training new employees. In turn, the improved visibility makes it easier to identify bottlenecks and spot opportunities for improvement.
It Drives Continuous Improvement
Standardized work is the foundation for continuous improvement or Kaizen. Here, it’s important to think of standardized work not as a rigid SOP, but as the current best-known way to complete a process.
Kaizen is a Japanese lean manufacturing term that can be translated to mean ‘small change’. Kaizen looks at improving processes by making a series of small, incremental changes. Having a standardized way to complete a task helps workers and managers find opportunities to make these changes. Something as small as reorganizing tools in a workspace may help save time and improve overall efficiency. When proven to be effective, these changes can then be standardized and implemented across the organization.
5 Tips to Implement Standardized Work
Any task or process that occurs repeatedly can be standardized. High-volume tasks prone to errors are prime candidates. This could include how machines are operated, cleaning procedures, packing processes, safety protocols, etc. To achieve this, you must have a clearly defined task, sequence of steps, time required for the task, and the desired outcome. Here are a few tips to help you get started.
Analyze current operations
Begin by studying your current operations and collecting data on metrics such as output rate, costs, internal interactions, etc. Also, note existing issues in product quality and processes as well as output variations. This will form a baseline for your efficiency and productivity analysis.
Document work sequences and takt time
Document each step in as much detail as possible along with the time it should be completed. If a task is currently being completed in varied ways, evaluate the different techniques being used, pick the most efficient method, and document it as the standardized way to complete the task. Processes can be documented in the form of SOPs, checklists, templates, work instructions, or other visual graphs.
Implement standardized workflows
Once the workflow has been standardized, it must be made accessible to all teams and implemented. This may involve a certain amount of training. The standardized workflows should also be shared with the teams so they know what is expected from them and can implement the new procedures in their daily routines.
Monitor and evaluate
Standardized work is not meant to be a rigid practice. It must adapt itself to new technology and continuous improvements. Hence, establish a system of checks to monitor the effectiveness of your SOPs and workflow. This may take the form of regular audits, collecting employee feedback, analyzing performance metrics, etc. Encourage and empower employees to make suggestions and implement small changes that may improve the existing system.
Make it easy to update
When a change is suggested and found to be effective, the standardized workflow must be updated to include the changed protocol. Then, roll it out organization-wide to keep everyone aligned. Here, it becomes important to make the workflows easy to update and ensure that everyone has access to the most recent version. Using digital visual management tools can help.
Digital Standardized Work for Lean Factories
Digital standardized work refers to transitioning from paper-based SOPs and work instructions to interactive formats such as fabriq digital visual management boards. This transition helps leverage real-time data, augmented connected worker solutions, and advanced technology to optimize operations with data-driven decisions.
To begin with, digitization automates data collection and breaks down silos to create a centralized knowledge base. This preserves institutional knowledge and makes real-time data easily accessible. Fabriq also simplifies information sharing. Unlike paper manuals, digital SOPs can be accessed from anywhere. It also lets you supplement written documentation with photos, illustrations, 3D models, videos, and more. This makes communication clearer and improves engagement. Maintaining a central database for standardized work instructions further eliminates ambiguity by ensuring that all employees refer to the most up-to-date version.
Getting Started with Digital Standardized Work
Digitizing Standardized Work with tools like fabriq goes a long way to improving productivity, delivering consistent outputs, reducing waste, driving continuous improvement, and operating efficient lean manufacturing systems. It also supports knowledge preservation and simplifies new employee onboarding and training.
Ready to bring your standardized work into the digital age? Request a demo and see the difference fabriq can make on your shop floor.
