Monday, October 10, 2022

Standard Work System of Toyota Production System

 

Shahrukh Irani

https://www.linkedin.com/posts/shahrukh-irani-8b25a55_flow-process-chart-rma-working-form-531-activity-6973468834372468737-Pqnv  

In this post, I would like to show (or at least try to show) that two of the charts that constitute Standardized Work are “tweaked” and improved versions of IE charts for Operations Analysis. 


STANDARD WORK COMBINATION TABLE: This chart is the IE chart known as the Flow Process Chart with the following modifications:


(1) the step-by-step processing of the product is shown in the rows of the chart,


(2) the four columns for non-value added activities in the original FPC (Manual Handling, Transportation, Delay, Storage) have been eliminated; only Operations and Inspections are described in the rows of the chart.


(3) since each processing step of the product usually requires one or both resources (Man & Machine), every row in the chart records how much time is required in the appropriate column.


(4) the right side of the SWCT is a Gantt Chart with the timeline going from 0 to Infinity. The duration of each step in any row (“Operation Time”) is shown on the Gantt Chart. Whenever the operator has to walk, his/her travel time is indicated in the Gantt Chart.


STANDARD WORK LAYOUT SHEET: This chart is the IE chart known as the Flow Diagram (or Spaghetti Diagram) with details about each step that were recorded in the Flow Process Chart being shown on the diagram; specifically, the SW version shows the symbols for Safety, Quality and Inventory (WIP count).  Could the Flow Diagram have been more than a bunch of lines? Sure, just overlay information from the Flow Process Chart for each activity on the different symbols shown on the Flow Diagram.


I think I understand why the three SW charts carry as much information as they do. They constitute a complete analysis to design an assembly process that meets a specified Takt Time per the demand for the product being produced at a single work station or in a single cell.


1989 TPS Handbook - Standardized Work - Detailed description

Toyota Standard Work – Part 1: Production Capacity
June 19, 2018 by Christoph Roser


Toyota Standard Work – Part 2: Standard Work Combination Table
June 26, 2018 by Christoph Roser


Toyota Standard Work – Part 3: Standard Work Layout
July 3, 2018 by Christoph Roser






Ud. 10.10.2022
Pub 19.9.2022












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