Templates for Lean Methodology

Lean Methodology Templates

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Standard Work

• Takt time calculation: Use this worksheet to calculate your Takt Time.

• Time observation: Use this document to prepare the time observation, by breaking the cycle into a standard sequence of work elements and by identifying for each the breakpoint or unique point that defines the start of a work element. Use 10 to 12 observations to determine the standard times.

• Standardized work chart: This template is used to illustrate standardized work for purely manual operations. One sheet per operator.

• Standard work combination sheet: This document is to be used only when you have operators moving and synchronizing with one or more machines or a fixed speed moving line. It represents the “choreography” of the operator, showing manual activities, automated machine cycles, and walking times. It ensures that the cell or line can operate within Takt time.

• Standard operations layout: Use this document to represent the walking motion of the operator inside of the work center, the placement of standard work in process, and other important process points. One sheet per operator.

• Standard work instructions: The standard work instruction sheet is used to describe in great detail how to carry out a job. The key points section of the sheet is an important difference with the more commonly used standard operating procedure. This document is the basis for the Job Instruction method (part of Training Within Industry—TWI).

• TWI Job Breakdown Sheet: This form helps you break down the job into work elements and capture for each the key points and the reasons for key points. The Job Breakdown Sheet forms the basis for how you train operators.
  

• TWI Training Time Table: Use this document to plan, schedule, and follow-up on your training sessions.
• Job Instruction Card: This is a summary card you can print and laminate and keep in your pocket. It gives you an easy-to-use reminder of the Job Instruction method and is similar to the original cards produced in the 1940s

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Flow Cell Design

• Production capacity sheet: Use this worksheet to determine that all equipment used in the cell or line has the required capacity to meet daily demand and to identify the bottleneck machine. Note that this document only covers the setup downtime related to changing tools, and doesn’t account for unplanned downtimes or quality losses.

• Takt time and crewing range calculator: This worksheet is used to determine the number of operators needed depending on the Daily demand, Available production time, Operator cycle time, and Number of shifts.

• Material handler workload template: This worksheet is used to design the flow racks feeding a cell and calculate the workload for the material handler. To use it, start with the routing sheet for the product being produced and for each component, collect the data concerning packaging, weight, dimensions, and material handling times.

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Other

• SMED study template: This observation/analysis tool is used determine potential improvements for changeover projects. Start with the current state tab, then move to the target state tab. Note that predicting the time savings from an action can be a complex matter that may require using a critical path software.

• Heijunka EPEI calculator: This worksheet helps you determine the leveling period for a work center (flow cell or line) based on multiple data such as changeover time, cycle time per product, OEE excluding changeovers, and average daily demand. Defining the actual leveling period is an iterative process, so the worksheet includes a simulation section.

• 6S Template: 6S (formerly known as 5S) is a proven way to organize your workplace to improve efficiency, enhance safety and overall well-being in your workplace. The following steps will outline steps to implement 6S and help you on your journey

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