the most powerful uses of standardized work is for analyzing and understanding
waste in the operation. The documented work procedure will be a visual repre-
sentation of the waste (opportunity for improvement) that exists. It is part of the
analysis that helps to remove the “clouds” and see the underlying image. It will
also provide beneficial information for establishing balanced work flow during
the creation of continuous flow.
In Chapter 6 we will provide greater detail on standardized work and how
it’s used to establish and document the standard method, but at this phase suf-
fice it to say that the tools are simply used to aid in identifying waste. There are
three critical elements in analyzing the work and identifying waste during the
stability phase:
- Identify the basic work steps.
- Record the time for each step.
- Draw a picture of the work area and the operator’s flow within the area.
Bear in mind that the intent is to identify waste, and it is important to start
with the “big” waste first. As an analysis tool, standardized work will primari-
ly aid in the identification of motion (walking, reaching) and waiting (when the
work cycle is below takt rate). It’s best to first analyze from a higher level and
then work down to a detailed level. If the work requires the operator to walk
out of the work area, we begin by identifying this major component. If the opera-
tor walks within the work area, we begin with the walking pattern. If the operator
is stationary (in a chair, or does not walk), we begin by observing his or her
hand motions.
There are no hard rules about how to document the work at this stage. The
objective is to record what is happening in such a way that the big waste can be
seen and understood by everyone. The level of detail for describing the work
steps is relatively basic. It is not intended to prescribe howthe work is to be per-
formed; rather, it is a description of whatis happening.
Since we’re looking for big waste, the general rule of thumb is to record each
time the operator takes a step from place to place for walking jobs or moves his
or her hands for stationary jobs. We are looking for the waste, and not neces-
sarily the details of what is being done at each step.
After the steps have been identified, the amount of time for each step is cap-
tured and recorded. Separate the time into two basic categories: work time, and
walking (or reaching) time. Finally, a bird’s-eye drawing of the work area is
made, the location of the work steps is added, and the steps are connected with
a line. This drawing is very important, and visually powerful. Make it large
enough to get a clear picture. Do not worry if the drawing looks “messy” with
too many lines and circles. That’s the point! When the picture is completed, look