Toyota Way Fieldbook : A Practical Guide for Implementing Toyota's 4Ps

126 THETOYOTAWAYFIELDBOOK

Standardized Work Documents

There are three primary documents used for developing standardized work,
and many other related or supporting documents. It is not the purpose of this
book to go in to detail on how to use each of these tools but it is worth saying a
bit about each of the following:

1. Standardized Work Chart

2. Standardized Work Combination Table

3. Production Capacity Sheet

Standardized Work Chart

Originally the document that Toyota used for the Standardized Work Chart was
primarily a diagram of the work area and worker flow. There was no verbal
description of the work method and no element times associated with each step.
The detailed element times were a separate document, such as the Standardized
Work Combination Table. Somewhere along the line in many operations the
Standardized Work Chart and the Standardized Work Combination Table were
blended into one simplified document that is often referred to (outside of Toyota
at least) as a “Standardized Work Sheet,” or “Standardized Work Chart.”
The Standardized Work Sheet is used initially as a tool to identify and elimi-
natewaste.After improvements are made, the new method becomes the baseline
for improvement. Then it is posted in the work area as a method of visual con-
trol for management to verify adherence to the standard.
As with any tool, its use is dependent upon the circumstances. What is the skill
of the user? What condition is being corrected? Do not worry about trying to
achieve a perfect result or using the sheet “correctly.” During the initial appli-
cation of standardized work in a process, the first step is to create a baseline for
improvement. The steps of the process are:

1. Record the sequence of the job (the work steps)


2. Diagram the work movement.


3. Identify waste


4. Determine improvements needed to achieve desired results (meeting the
   takt time is an objective that is explained below)


5. Incorporate material usage and flow (standard in-process stock)


6. Document improved method
   Figure 6-5, below, provides an example of a Standardized Work Sheet. The
   main elements are the work sequence and the diagram of the work movement.
   Once the steps and diagram of the work flow are completed we ask the question,
   “What do you see?” Look at the diagram and describe your initial impression.