182 Pages 247 Color Illustrations
    by Productivity Press

    182 Pages
    by Productivity Press

    182 Pages 247 Color Illustrations
    by Productivity Press

    This field guide can be used directly on the gemba (work area) for implementing and documenting standardized work. It promotes the "future state" of standardized work along with crucial step-by-step techniques and explanations not found in other publications. The authors furnish many real examples of work problems that cause Lean practitioners difficulty with documentation, along with accurate solutions to those problems. The many illustrations and graphics focus on practice rather than theory. Readers learn that standardized work is not simply a tool for documentation but a method for reducing variation and providing continuous improvement through kaizen.

    How to Use This Field Guide

    Layout Sketch: Where It All Begins
    Basic Layout Sketch Rules
    Some Problems Are More Complicated
    Food for Thought

    Questions for Layout Sketch Review
    Answers for Layout Sketch Questions

    Standardized Work Chart: Building on an Idea
    TT and Desired Cycle Time
    Some Tips on Choosing Start/Stop Points
    Simple Stopwatch Method
    Memory Stopwatch Method #1
    Memory Stopwatch Method #2
    Summary of the Three Stopwatch Methods
    Food for Thought
    Some Other Information on the SWC

    Questions for Standardized Work Chart Review
    Answers for SWC Questions

    Work Combination Table: Where Time and (Work) Space Collide
    How-To: WCT
    Meanwhile, Here in the Work (Real) World
    Real-World Problem: OCT > TT
    Real-World Problem: OCT < TT (and Forced Wait at End of Work Cycle)
    Real-World Problem: Forced Wait during Work Cycle
    Real-World Problem: Showing Work Elements with No Walk between Them
    A Dose of Reality: Some Problems Are Much More Serious
    Real-World Problem: Work Sequence Does Not Match Geographic Sequence
    Real-World Problem: Worker Returns to Same Location during Cycle
    Real-World Problem: Parallel Machines Due to Excessive Machine Cycle Times #1
    Some Problems Seem Impossible to Resolve
    Real-Life Example: Parallel Machines Due to Excessive Machine Cycle Times #2
    Do Not Get Hung Up: Some Rules Are More Like Guidelines
    Sometimes, We Outsmart Ourselves
    Some Food for Thought
    Watch Your Step: Waste Is Everywhere
    Real-Life Example: Changing the Unit of Flow during the Worker Cycle

    Questions for Work Combination Table Review
    Answers for WCT Review

    Where Do We Go from Here?
    Man–Machine Utilization Graph
    Task Summary Sheet

    Questions for Miscellaneous Tools Review
    Answers for Miscellaneous Tools Questions


    Timothy D. Martin worked in manufacturing engineering for more than 32 years in the electrical and electronics industries. He has been a Lean practitioner for more than 20 years and has a broad range of continuous improvement experience, including extensive hands-on Lean implementation. Since 2010, Tim has been working to implement Lean transformation in the healthcare industry. He earned a BSEET from Purdue University and a MSM from Indiana Wesleyan University. He also is co-author of New Horizons in Standardized Work: Techniques for Manufacturing and Business Process Improvement , with Jeffrey T. Bell. Jeffrey T. Bell has over 25 years in the aviation manufacturing and automotive electronics manufacturing sectors where he designed numerous manufacturing systems using standardized work as a basis. He earned a BSIE from Kettering University and a MSE in Industrial Engineering from Purdue University. Scott A. Martin is a freelance artist/illustrator and business manager living in Birmingham, Alabama. His most recent works include book illustrations and website designs in digital media, although he also is experienced with other forms of traditional art, including pencil, ink, oil, and acrylics. He also is an amateur sand sculptor, pumpkin carver and print maker. Scott studied communications at the University of Alabama.

    "The real power of Lean occurs when a specialized technique that is typically practiced by a highly technical person, such as an industrial engineer, is taught, understood, and used by an everyday person. I love what Tim and Jeff have created! They have brought standardized work into the realm of understanding of anyone. I do not think that I have seen anyone take a dry subject like this and make it so fun, engaging, and interactive. The Standardized Work Field Guide kept my inner five-year-old child entertained and wanting to turn each page. It is clearly written and explained in language that mere mortals can understand. The drawings help make the material interesting and fun. The fun and interactive nature of the book helped to embed the learnings more deeply. The exercises and the examples are practical and represent real-life situations. I learned a number of tips about standard work that I had not understood before. This is now my go-to book on standardized work."
    Joseph Swartz, administrative director, business transformation, Franciscan Alliance, Inc.

    "This guide is intended to be a workbook that walks you through the development of your standardized work. I encourage you to take it to the gemba and use its templates and tables to document your processes as they exist today. It is through its lessons, exercises, and repetitive use that you will gain experience and confidence to develop your documentation and reduce variation to create a better product. I hope you enjoy the book and the lessons as much as I did."
    Brian W. Hudson, senior advisor, Lean Six Sigma Purdue Healthcare Advisors