Improvement based on standardized work: an implementation case study

  • Julio Cesar Fin University of Caxias do Sul
  • Gabriel Vidor University of Caxias do Sul
  • Ivandro Cecconello University of Caxias do Sul
  • Vanessa de Campos Machado University of Caxias do Sul http://orcid.org/0000-0002-0446-6495
Keywords: Standardized work, Waste reduction, Process optimization, Toyota Production System, Medium chassis assembly line.

Abstract

Standardized work is an effective way for process improvement, specially when it is applied to manual tasks such as assembly lines. This tool is part of Toyota Production System and based on wastes reduction. Thus, the objectives were to implement standardized work in a medium chassis assembly line and measure the benefis from optimization of operators’ tasks and movement through waste reduction. In order to achieve these results, a single case study was performed in a medium chassis assembly line that is part of a company in South Brazil. The steps involved: defining the object of study; time measurement and takt time definition; creating a production capacity sheet; defining the minimum number of operators and balancing the line; determining minimum work in process; defining the new layout; creating a standardized operations sheet and a standardized operations routine sheet; training and implementing standardized work; and verifying the results. Results show 36 minutes reduction in terms of assembly time and 200 meters reduction in terms of operators’ movement on average. Other contributions regard the 9.6% reduction in terms of the assembly line downtime.

Author Biographies

Julio Cesar Fin, University of Caxias do Sul
Engenheiro de Produção - Universidade de Caxias do Sul
Gabriel Vidor, University of Caxias do Sul

Coordenador - Programa de Pós-Graduação em Engenharia de Produção - Universidade de Caxias do Sul

Professor - Programa de Pós-Graduação em Administração - Universidade de Caxias do Sul

Doutor e mestre em engenharia de produção - Universidade Federal do Rio Grande do Sul

Engenheiro de Produção - Universidade de Caxias do Sul

Ivandro Cecconello, University of Caxias do Sul

Doutorando em Administração - Universidade de Caxias do Sul

Mestrado em Engenharia de Produção - Universidade Federal de Santa Catarina

Mestre Assistente - Universidade de Caxias do Sul

Engenheiro Mecânico - Universidade de Caxias do Sul

Vanessa de Campos Machado, University of Caxias do Sul

Bolsista CAPES/PROSUP

Mestranda em Administração - Universidade de Caxias do Sul

Engenheira de Produção - Universidade de Caxias do Sul

Published
2017-09-06
How to Cite
Fin, J., Vidor, G., Cecconello, I., & Machado, V. (2017). Improvement based on standardized work: an implementation case study. Brazilian Journal of Operations & Production Management, 14(3), 388-395. https://doi.org/https://doi.org/10.14488/BJOPM.2017.v14.n3.a12