Standardizing work for varied productio
I work in a manufacturing lab that produces products for clinical diagnostics. We make reagents, calibrators, and controls for a wide range of blood, urine, etc. tests. There are over 300 different products produced by our department. There are many common aspects between the products but the actual manufacturing processes vary greatly. I am looking for ideas on how to standardize work through out the department.
I didn't find the right solution from the Internet
I feel your pain, I am in the construction industry. Site conditions change drastically from job site to job site. Scope of work changes from job to job as well. As soon as one task is completed, you might need a whole different set of tools, different crew, etc.. to keep the job going. Weather delays, can throw a big wrench in your plans.
What I first did was try to standardize everything.
-Every job the first thing that happens is lighting, goes up. Then we clean our work area. lay down our drop cloths, cover everything that could be negatively impacted with plastic, plywood, whatever it takes.
-I stage a tool corral, that I try to replicate every job. As close to the area that we're working that I can. (sometimes we could be working in huge industrial buildings a couple 100 thousand sq feet. If someone needs to run across the building it could be very time consuming. Also I get super frustrated looking for tools/fasteners, I want everything as close to the same place every time.)
-what ever task we're doing then we only bring out the tools required to complete that task. (so if I am wearing a tool pouch that day, I'am not loading it up with a bunch of tools and fasteners just cause I can. I am only taking with me the tools I need to complete whatever task needs to be completed. Also as far as the site goes, I am also not bringing material out, or any larger tools/equipment till probably the day its needed.)
-Then we put everything away if theres any cleaning that is needed, sawdust, dirt, broken concrete, etc.. it gets cleaned up immediately. We move on to the next task. (client, inspector, architect, engineer, anyone that walks on to my job site I want to think "wow this is how all job sites should look")
The biggest thing I can tell you is maybe focus on the similarities, how to standardize that. Keep all the variables being equipment and material in a orderly fashion so when you need them you can retrieve them effortlessly. Once your there try to eliminate steps. Try to take notice of things you truly don't need, and get them out of there.
I am certainly guilty of organizing waste, and there's nothing lean about that. I hope that helps. post up some more details if you can and I will try to help the best I can.
First of all, what you need to understand is the concept of standardization is very simple. It’s been applied to everything from making hamburgers to flying planes around the world i.e. Southwest Airlines. Henry Ford understood this concept when he made the Model T. The same concept is translated into any pursuit, whether it be in the service industry or in the manufacturing industry.
The key to Lean is very simple. Most people prefer to complicate it. Understand that everything you do in life from brushing your teeth to making your lunch to managing your health is a process. There are no exceptions to this rule. Contained in every process is an abundance of the eight different kinds of waste. Learn to see the waste in these processes. Eliminate the waste by making small improvements look for every opportunity to standardize every process reducing the variation that is typically associated with most work.
First start with yourself. Standardize your work and the things you do every day. Then you will gain a keen understanding of what’s standardization can deliver and really mean. You have enough waste for 10 lifetimes. Never look at anyone else just start improving you! Lean is no more or no less than this it's that simple.