How to write a Standardized Work Chart that Toyota created【Excel Template】

Toyota has various famous tools and methods such as the ‘Kanban System’, ‘One Piece Flow’, etc. They cascade those effects to the frontlines with this ‘Standardized Work Chart’. This article explain how Toyota utilizes the Standardized Work Chart and how to use its Excel template.

How to write a Standardized Work Chart that Toyota created【Excel Template】

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DOWNLOAD  ← Click this to download the “Standardized Work Chart” template file.

 

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What’s ‘Standardized Work Chart’ that enables you utilize Takt Time in practice?

Hi, this is Mike Negami, Lean Sigma Black Belt.

 

I received this request on the video about Takt Time the other day.

 

Standardized Work Video Request

“Can you make a Standardized Work template and introduce it?”

 

Standardized Work is a method that Toyota established. It consists of three elements: ‘Takt Time, Working Sequences, and Standard In-Process Stock’, and is used in each workplace as the ‘Standardized Work Chart’.

 

Since this episode will be more detailed than the previous one, those who haven’t watched the Takt Time video, please read the article first.

 

 

Toyota has various famous tools and methods such as the ‘Kanban System’, ‘One Piece Flow’, etc. They cascade those effects to the frontlines with this ‘Standardized Work Chart’.

 

Furthermore, in order to create the ‘Standardized Work Chart’, it’s necessary to create a ‘Standardized Combination Table’. In order to create this ‘Standardized Combination Table’, it’s necessary to make a ‘Production Capacity Sheet’. We call these three sheets ‘the 3 tools of Standardized Work’. I’ll explain each tool.

 

Introduction of the 3 Tools of Standardized Work

 

At Toyota, they first make a ‘Production Capacity Sheet’. This below is an example of that document.

 

Production Capacity Sheet

 

It records current work procedures, actual manual work times, machine running times, and numbers of each production in a certain time that are recorded with a stop watch. This enables us to check the problem process that becomes a bottleneck.

 

Next, this is the ‘Standardized Combination Table’ that was created based on the ‘Production Capacity Sheet’ and is written in further detail. With this document, since you can visualize your manual work time, the machine running time and the walking time of each step and compare it with its Takt Time, which is the standard time, it becomes clear where and how much improvement should be made. That way, you’ll reduce any walking waste and waiting waste of workers and machines, and improve the target process to include the safest and most efficient procedures.

 

Standardized Combination Table

 

Lastly, make a ‘Standardized Work Chart’, which is today’s theme. This is an example of the chart. It describes the placement of equipment, the movement of people and the work procedures. The Takt Time, Working Sequences and Standard In-Process Stock, which are the three elements of Standardized Work should be included.

 

Standardized Work Chart

 

How does Toyota use the ‘Standardized Work Chart’?

 

The last tool the ‘Standardized Work Chart’ is the most important. Toyota reviews their production quantities every month, then they update the ‘Standardized Work Chart’ every month as well. Since they do that for all their workplaces, it must require great effort. That’s how much Toyota values this ‘Standardized Work Chart’.

 

Their front-line supervisors are in charge of making and maintaining this document. The key is that they patrol their sites and make sure all their workers follow the Standardized Work thoroughly. Furthermore, since they regularly revise the ‘Standardized Work Chart’, their Standardized Work will be improved each time. They’re doing this company-wide. Toyota is a really special company.

 

Make your Standardized Work Chart with the ‘Cycle Time Measuring’ template.

 

If you can make a ‘Standardized Work Chart’ by analyzing with the ‘Production Capacity Sheet’ and ‘Standardized Combination Table’ as I mentioned, the improvement would be very big.
However, the bar is a little bit too high for us to do all those tools on our own, so I only made the template of ‘Standardized Work Chart’ this time and will introduce another way to complete the document.

 

I made a template in the past that can measure cycle time. Since you can complete production leveling, which is Heijunka with that template, you can analyze and improve your process.

 

 

 

After that, it’s a good idea to record the improved process in the ‘Standardized Work Chart’ template.

 

How to use the ‘Standardized Work Chart’ template.

 

DOWNLOAD  ← Click this to download the “Standardized Work Chart” template file.

 

This below is the Standardized Work Chart template. The instructions are written on the right side. First, fill out each step of the improved process in this left column. Be aware that each step has a step number.

 

Standardized Work Chart Template

 

Next, copy and paste this equipment icon and arrange your equipment locations. You may want to label each piece of equipment on the icons. You can copy them easily by dragging the shape while pressing down your control key.

 

Arrange Equipment Icon

 

Next, arrange the step numbers according to the movement of the workers. Then connect them with solid arrows in order of step number. Use a dashed arrow to connect the final number and Step 1.

 

Arrange Step Numbers

 

Connect with Arrows

 

Here are three special symbols. Use this diamond symbol to clarify steps where a quality check is necessary. Use this cross symbol where special safety attention is needed and use the black circle symbol where you keep Standard In-Process Stock. This is the completion of the Working Sequences, which is one of the three elements of Standardized Work.

 

3 Special Symbols for Std Work Chart

 

Lastly, please fill in the other 2 elements, the number of Standard In-Process Stock and Takt Time, below, then it’s completed.

 

Standardized Work Chart Completed

 

This method was developed by Toyota. It might be difficult to do thoroughly the way they do, but let’s try to at least make the Standardized Work Chart. That will be the first step towards improvement. “There is no improvement without standards.”

Comments

  1. Mariano says:

    Thank you very much for your guidance and support! I am just starting a new job as a Project Manager and you simplify LSS and PMO a lot. Greetings from Costa Rica!

    • Mike says:

      Hi Mariano – I’m glad to hear my site is useful for your work. Keep it up. If you have any questions, let me know. Mike

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