I
STANDARDIZATION
K
01/27/2025
E BY: KIBROM M.
Ethiopian Kaizen
Institute 1
Contents
1. Standard
2. Standardization
3. Workplace Standardization
4. Operation standardization and its benefits
5. Standard operation sheet
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1. STANDARD …???
• Standard defines the acceptance criteria for
judging the quality of an activity.
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Pyramid of Standard
World ISO, IEC
Regional CE marking
Standard
National Standard Engineering standard
Industry Standard ASME
Company Standard
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• In the Kaizen context Standards refers to rules,
procedures and guidelines for activities carried
out in the workplace.
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Toyota production system
Taiichi Ohno
No standard , There can be No Kaizen.
1. There can be no basis for comparison (before/after)
2. One cannot objectively tell if there was a difference or
change
3. No improvement is possible in regards to Time,
Quality, Quantity, Cost, etc.
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2. WHAT IS STANDARDIZATION ??
Standardization is Formulation, publication, and
implementation of guidelines, rules, and specifications.
Is a standard specification, unit, instruction or something
that is understood globally.
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Why Implement Standard Work ?
To make it possible to identify and eliminate variations in
operators’ work.
Team member choices are dramatically reduced,
eliminating the “do it your own way”.
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Why Implement Standard Work ?cont…
Abnormal conditions are clearly defined and tracked.
To sustain the gains achieved from improvement
activities.
To provide a baseline for future improvement.
Promotes effective teamwork by teaching employees
similar terminology ,skills and rules of play at the work
place (GEMBA).
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Why Standardize? Cont…
Kaizen will succeed only if you pay regular
attention to Standard Work.
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KAIZEN and STADARDIZATION
Standardizati
on
Level of
Continuo
us result
Standardizati
on
Continuo
Improvement
us result KAIZEN
Standardizati
on
Case without
standardization
Time
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Standardization
Reduces Variation
Enables Flow
Eliminates Waste
Fuels Continuous Improvement
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Steps to Standardization
1. Identify and set a standard
• The standard method must be established and should be
regarded as a “good” method.
• But the standard method is only “good” - not “best”.
Each method challenges us for a better way-
Continuously improved.
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Steps to Standardization con’t…
The consistent updating of Standard Operations is the
cornerstone of Continuous Improvement.
2.Ensure everyone in organization understand & commit to
the standard.
3.Confirm the standard is reasonable & fair.
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Continuous Improvement
• Improving every aspect of every activity every day –
Forever.
• Think of continuous improvement as a journey
rather than a destination.
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Continuous Improvement con’t…
• Continuous Improvement enhances “people
supportive practices”.
– provides new skills to employees, empowering them to
design and improve their own work.
– by standardizing on a new method, it gives people the
ability to reduce variation.
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Continuous Improvement is needed:
• Increased competition
• Customer demands for lower prices
• Expectations for higher quality
• Changing technologies
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Continuous Improvement is needed con’t…
• For improved participation and self-direction
• Wider base of knowledge
• Safer, better workplace
• Zero accidents
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9 Continuous Improvement Process Steps
1. Observe current method
2. Document current method
3. Identify improvements (steps to eliminate)
4. Implement improvements
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9 Continuous Improvement Process Steps cont…
5. Validate quality and productivity of new method
6. Standardize new method
7. Document “Before” and “After” conditions
8. Recognize achievements
9. Look for next improvement
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3. work place Standardization
Make the work place ready and standardize for operation.
Basically we use 5S and layout for workplace standardization.
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Standardization is waste Elimination tool
Standard
Correct Clear &
deviation Make standard
Understandable visible
workplace
Report Discover
deviation Deviation
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4. Operation Standardization and its Benefits
4.1 Standard Operation
•It deals with detailed procedures to perform an operation
efficiently by anyone assigned for the task.
• An efficient production system which eliminates
wasteful procedures by bringing together a number of
jobs focused on the movements of workers.
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….Standard operation
cont’d
A method to make production efficient and orderly
by organizing all jobs around a worker’s movement.
All I need to do is to follow the same cycle !
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• In the KAIZEN context standard operation means
creating a consistent way that an operation or a task is
performed so that anyone can perform it.
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Standardized processes are intended to:
• Ensure customer satisfaction
• Drive consistent output
• Ensure consistent quality
• Drive consistent cost and time
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Standard operations apply to:
• See and Check operational problems.
• Ensures that the results will be predictable and
repeatable.
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4.2 Benefits of Standard Operation
• Ensure Safety
• Stable Quality
• Reduce cost & Increase Productivity
• Visualize what is normal vs. abnormal
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Benefits of Standard Operation cont…
• Stabilizes delivery times
• Eliminates Wastes
• Simplifies process
• Create base line for KAIZEN
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4.3 Objectives of Standard Operation
• To clarify the rules for the production/service
provision method.
• To decide the procedure with due consideration for
quality, volume, cost , safety and service delivery.
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……Objectives of Standard Operation con’t
• To grasp the current status of the operation and
find out what is wasteful, uneven, and
overburdening.
• Analyzing operations and making corrective
measures.
FASTFOOD
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Question
There are 3 stages, 12m
separated by each
others .Bridge is needed to
connected between
12 ｍ 12 ｍ stages. However there are
only 3 pcs of plate with 9 m
long provided. So, how to
do?
12 ｍ
Answer
As below picture, all
plate joint together at
the center of all stages
Wish for something
that hard or impossible
to get will cause Kaizen
stuck
12 ｍ 12 ｍ
Kaizen is proceeded by
using only 「 thing +
12 ｍ intelligent 」
4.4 Three Elements of Standard Operation
1.Takt time
2.Operating Procedure
3.Standard in process stock
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TAKT TIME
• The rate at which the end product or service must be
produced and delivered in order to satisfy a defined
customer demand within a given period of time.
• Is the time that is allotted for making one unit of
product.
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Takt time con’t…..
It is calculated as:
Takt time = Available work time per day
unit demanded per day
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Example If a process runs 24 hours a day with 2 hours
stoppage and the market demand is 220 entities per day
then:
Takt time = ((24-2)x60) minutes
220 units
= 6minute per unit.
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• Cycle time is the actual time taken to produce one unit of
product.
• Takt time concept aims to match the pace of
production with customer demand.
Start of Operation Standard
Takt Time
Cycle Time (1)
Cycle Time (2)
Waiting Delay
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Problems Caused by Late and Ahead Tact time production
• Late Takt time production
Dissatisfied customer
Rushes and overburdens
In process waiting
• Ahead of Takt time production
Overproduction
Idle time
Inventory
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Standard in Process Stock
Minimum Number of Goods In-process Required
It is the minimum quantity of parts always on
hand for processing during and between sub-
processes.
It allows workers to do their jobs continuously in
a set sequence, repeating the same operation over
and over in the same order
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5. Standard Operation Sheet
Standard operation sheet is a document that describes the
standard operation of a Specific operation.
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5.1 Procedure Standard Operation Sheet
1. Enter the layout of facilities and pallets in the
sheet.
2. Observe the target operator closely.
If the “waiting” is expected during operation, it is
also necessary to decide the point of waiting and
the timing to resume the operation.
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Procedure cont…
3. Enter operator’s movement using numbers and flow
lines in line with the procedure.
4. Record work elements and time measured in numerical
order.
5. Enter the quantity of Standard In-Process Stock (*) in
the bottom of the format
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Procedure cont…
6. Enter the items about quality inspection and safety
operations in symbols, if any.
7. Enter the information necessary to help control and make
follow up actions afterwards.
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Standard operation sheet as an Example
Plant: ACME Product: Pinion gear
ACME Corp.
Area: Machining Op. 1 of 1
Standard Work Chart Process: Exercise Pg. 1 of 1
Date: By: Approved by: Shifts: 2 Takt Cycle
2- 2- 2010 J ohn T. Alex S. Volume: 600 Time: 44.5 sec. Time: 44 sec.
Auto Time
Walk Time
Wait Time
Man Time
Working sequence Safety Swip Quality
Number Major Steps Walking
QC
Return to start
1 Pick up raw material 1 - -
2
2 Unload, load part and start M/ C GC618 4 38 -
2 CH- 238 CH- 618
3 Unload, load part and start M/ C GC234 6 7 -
2
4 Unload, load part and start M/ C GC144 6 38 -
2
5 Unload, load part and start M/ C GC145 5 30 - 3 2
2
6 Unload, load part and start M/ C TS117 7 3 - Raw
2 CH- 144 1
7 Pack FG in pallet 1 - - Material
2
4
Raw
7 Material
5 6
CH- 145 CH- 117
30 0 14
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WHERE SHOULD THE STANDARD WORK SHEET
IS POSTED …….??
Near to the workshop…?
In the supervisor office…?
At the work station……..?
In the operator pocket…?
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• The data about the status of operations such as
efficiency and “Muda” defined by the use of “Standard
Operation Sheet” can be analyzed and the corrective
measures can be worked out.
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• “Standard Operation Sheet” is subject to
change after examining the effects of the
corrective measures at the working site
discussing with operators there.
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4.2 Principle of Standard Formation
• Enhanced : Standard of Improved situation.
• Acceptability: Acceptable Standard to all employees.
• Practicality: Easy to Implement Standard.
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Thank You
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