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LEAN SIX SIGMA WORLD CONFERENCE ABSTRACT

Lean Standard Work, a Concept for Every Environment?

Presenter:

Ricky Banks, Lean Deployment Manager, United States Gypsum, Scottsboro, AL, USA

Keywords:

Lean Methodologies, Lean Standard Work, Lean Concepts

Industry:

Manufacturing

Level:

Intermediate

Lean Standard Work, a concept for every environment? In deploying Lean within USG we have learned many valuable lessons. One lesson, crucial to any lean deployment, involved learning and deploying the lean standard work concept. In a manufacturing environment in which some associates are utilized as machine tenders, standard work can be a difficult concept to grasp. We want to share our learnings and help others understand how this integral concept and tool of lean can and will work in any environment.

  • Standard Work overview

o Definition – Standard work is an integral part of lean manufacturing.

o The goal of standard work within a process is reducing variability in job performance by documenting and training operators “the best way we know today”, to perform that process.

o The impact of standard work upon the organization is the personal behavioral development of associates while achieving the required outcomes in Quality, Safety, Delivery and Cost

o Relation to problem solving

  • In a process or service, a problem can be linked to one of three conditions:- Lack of a standard.- The standard was not followed.- The standard is insufficient.

  • Methodology

o Standard Work and Lean Methodology

  • Work design with the intent of organization learning built in.

  • Problem identification, what is standard/Normal?

  • Developing Lean Leader Behaviors

  • Problem solving

  • Accountability

  • Leader Standard Work

  • Prerequisites

o Work is performed manually.

o Work has repetitive aspects

o Work is key to the management of the organization.

  • Components of Standard Work

o Takt time or cycle time of steps is important

o Precise work sequence is important

o Standard Work In Progress is important.

  • Standard Work Types

o Leader Standard Work

o Operational Standard Work

  • Training documents

  • Visuals

  • Settings

o Process Adherence Standard Work

  • Visual documents to be used by leadership to assess adherence to performance standards.
  • Continuous Manufacturing (utilizing machine tenders)

o Product manufacturing process

o Employee/machine interaction

  • Where do we start? Developing a plan for developing standard work.

  • How Standard Work has helped us!

o Discovered the importance of standardized processes in identifying normal/abnormal conditions.

o Benefits of standard work when bringing on new associates.

  • Quick understanding of purpose and common objectives

  • Faster onboarding times, with higher degree of success.

  • Higher degree of team effectiveness through Gemba walks and coaching toward;

  • Problem Solving

  • Accountability

  • Adherence to process.

  • Breaking down of ‘Silos’

  • Standard work integration pitfalls

o Important concepts/needs

  • Repetition – what does repetitive mean in relation to standard work?

  • Important to the management of the business – What qualifies as important?

  • You can’t ask people to adhere to a non-standard process. (how are our operational standards)? (“Where there is not standard, there can be no kaizen”, Taiichi Ohno)

Call for Proposals

Proposal Submission Deadline:
October 11, 2019

Acceptance notification date:
November 11, 2019

Early Registration Deadline:
February 11, 2020

Please make sure to review and prepare the material needed before you start the on-line Proposal Submission Form. Click here to see Proposal Submission Guidelines.

Who May Submit: This online form may be used by a principal speaker, co-speaker, contact person, or a committee member submitting on behalf of a speaker.

Multiple Proposals: You may submit multiple proposals.

Conference Registration Fee:
The conference registration fee is waived for the principal speaker of accepted proposals. Speakers are responsible for their travel expenses and arrangements. Co-speakers will receive a 30% discount for the conference that they are presenting at.

Length of Presentations: Technical sessions are typically 35 minutes. There will be a limited number of "double" sessions, 70 minutes, at the end of each day.

You will need the following to submit a proposal

Proposal Title: Maximum 80 characters including spaces. 

Keywords:Please include three keywords with a maximum of 100 characters, including spaces. 

Industry Sector: Please select the most relevant Industry sector for the proposal from a list.

Abstract: The Abstract should be 1,500 to 5,000 characters (note that it is Characters, NOT words), including spaces.

Biography: The Biography must be 1,500 to 5,000 characters, including spaces.

Public Profile: LinkedIn or Public Profile for link for the Principal Speaker: 

Speaker's Photo (optional)

Sample Video (optional)

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