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Good quality input resources: If parts and materials are of insufficient quality, the processing conditions will always be changing. Since quality is built into the product in the process, every time defects occur in process due to defective input material, they will require an investigation into the cause that is beyond the scope of the process itself. This leads to unstable processes and consequently standardized work will no longer function as intended.

3.5 Types of Standard Work Documents

To avoid creating a standardized work sheet for each product, all standard work is documented on a more common basis. The standardized work is created for the following cases:

3.5.1 Set up sheet: The absence of documented set up procedure presented the biggest problem in the processes. Set up involves the elements of work that take place between completion of the previous job and start of the new job. This includes cleaning, loading the program. No documented set up procedure and time procedure was in place to guide the operator in carrying out set up. As a result, set up method and time was hugely variable with each operator claiming his or her method to be superior to that of his/her co-worker. With the new standardized set up sheet each setup time is monitored and non value added time is continuously eliminated from the process.

3.5.2 Standard Operating Procedure: This contains the work instructions needed for the operator to perform his or her work. This is used to describe a single activity. It is important to display all the knack points for the operation. Knack points are special key techniques (tricks of the trade) that enable the job to be done effectively and may relate to any aspect of performance including quality, efficiency, burden and productivity. It is helpful as a visual document with pictures that enable the operators to positively respond rather than paragraphs of text that take time and difficulty to understand. Pictures, icons and symbols can convey operator work effectively. This document will also be a very good training document for new operators.

3.5.3 Pre Job Review: This is a very important document which should be completed before the operator/ machinist can start working. This document is a combination of all the activities including the right tool, right part, material and it also includes the cost of the part which could give the machinist a sense of importance of the product he/she is handling. The pre job review document travels with the work pallet, the production control initials it confirming the right part is supplied to the shop floor, later the machinist signs it indicating he has received the right work piece later this is initialed by the tool crib indicating the right tools are supplied to do the particular job. With this document the entire history of the work piece can be found out, and in case of any mistake it is very easy to identify the place where the mistake has started.

CHAPTER 4:

Lean Production

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