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Standard Work is Kaizen Instruction for Managers

Avatar photo By Jon Miller Updated on May 18th, 2023

Standard Work may be the most important Lean manufacturing tool that you don’t know enough about. Built on the three elements of takt time, work sequence, and standard work in process (standard WIP), it is the cornerstone of the Toyota Production System.

Differentiating Work Instructions from Standard Work: A Clear Perspective for Managers

Numerous managers are becoming more acquainted with Standard Work, inspired by its application at Toyota, and are eager to adopt it in their own factories. However, misconceptions persist. Standard Work isn’t merely about setting work standards or crafting operator instructions. Its essence is centered on providing kaizen, or continuous improvement instructions for managers.

Many managers like the idea of Standard Work because they see it as detailed work instructions for the operators. The Standard Work Instruction Sheet is used as part of the work instruction documentation, but the Standard Work Sheets and Standard Work Combination Sheets are meant for visual management, not work instruction.

Visualizing Kaizen Opportunities: Manager’s Insight from Standard Work Review

By recording the optimal blend of manpower, machines, and materials, these two documents set the performance benchmark for the line or cell. Any deviation observed calls for kaizen – continuous improvement. This approach forms the basis for managing abnormalities.

For instance, discrepancies in operators’ cycle times leading to wait times can be spotted on the Standard Work Combination Sheet, signaling the need for kaizen. Standard Work Sheets delineate the correct work sequence on a work area layout and highlight safety and quality checks. Managers reviewing the Standard Work can quickly identify areas requiring kaizen.

Unleashing the Power of Standard Work: Kaizen Instruction for Managers

Standard Work is much more than a way to document the standard and create work instructions for the operators. Standard Work is kaizen instruction for managers who go to the gemba to observe the process. Stay tuned to this blog to learn more about Standard Work, or if you can’t wait, get your Standard Work here.

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Jon Miller

Jon has dedicated his 25+ year career to the field of kaizen, continuous improvement, and lean management. Jon spent the first eighteen years of his life in Japan, then graduated from McGill University with a bachelor’s in linguistics.

  1. Ann Hamon

    June 12, 2021 - 1:50 pm
    Reply

    I believe standard work makes everything flow easier. It makes changeovers faster and more effective.

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