31
5
Collecting Data
If there is anything Daniel had learned over years of giving training, it was
the power of a step-by-step approach. He always told his young colleagues,
“Break it down into small pieces, go for the step-by-step approach and
people will digest it better. Moreover, it gives a lot of structure to the
teaching.” Training data collection was no exception to this rule. To ease
the conveyance of the knowledge, Daniel craed a step-by-step approach
that he was about to unveil to the trainees.
TASK ONE: GROUP FORMING
Daniel described the rst task:
Form groups of four people. e general rule is that each group should
include people with dierent backgrounds. When the work is done on
the shop oor, please make sure that at least one operator is included.
is is the most eective way to carry your message to the shop oor and
spread success.
One minute later, the ve groups were formed. Daniel wrote down the
names on the ipchart, and then presented the layout with the position of
each team (Figure5.1). e room that was used for training was suddenly
transformed into a T-shirt packaging factory with four workstations, one
for each group.
32  •  Implementing Standardized Work
TASK TWO: TEAM ORGANIZATION
Daniel now moved to the description of the second task:
Each team should pick an “operator.” is person will be the operator
during the simulation. You also need to designate a stopwatch keeper and
a time collector. e stopwatch keeper will read the times loud enough
for the time collector to be able to write them down on the sheet of paper
Ijust handed out to you (Figure5.2). e fourth person of the group, the
press-handler, will be in charge of the press. Why do we need a person to
be in charge of the press? e press, which is supposed to be an automated
machine, is in reality just a piece of folded cardboard. erefore, we need
somebody to make it operate like an automatic machine. Every time the
operator closes the press and pushes a factice button, the person in charge
of the press will start the stopwatch and open the press 10 seconds later to
emulate an automated operation (Figure5.3).
T-shirt Bin
(1)
T-shirt Bin
(4)
T-shirt Bin
(3)
Press
(2)
Folding Table
(2)
T-shirt Bin
(2)
Shared T-shirt storage
(1 & 2)
1
2
3
4
Shared T-shirt storage
(3 & 4)
Press
(3)
Folding Table
(3)
Folding Table
(4)
Folding Table
(1)
Press
(1)
Press
(4)
Daniel’s Table
2
3
4
1
2
2
3
4
3
4
1
1
Layout of the Room for the Simulation Training Module
FIGURE 5.1
Layout showing the position of the four teams.
Collecting Data • 33
Machine:
Realized By:
Date:
Station:
Time: Process Cycle
# Operation Element 12345678910 11 12 13 14 15 16 17 18 19 20 Mode Min Max Average
Measured Time:
Measured Time:
Measured Time:
Measured Time:
Measured Time:
Measured Time:
Measured Time:
Measured Time:
Measured Time:
Measured Time:
Comments: Note reason for special cause variation, material change, code change
1
6
2
7
3
8
4
9
5
10
Time Collection Sheet
1
2
3
4
5
6
7
Special Cause Time
8
9
10
Total Process Cycle Time
FIGURE 5.2
Time collection sheet.
34  •  Implementing Standardized Work
A few minutes later, all teams had picked an operator, a stopwatch
keeper, a time collector, and a press-handler. e whole group was now
ready for the third task.
TASK THREE: FACILITATOR GIVES
JOBINSTRUCTIONS FOR OPERATORS
Daniel proceeded with the description of the third task. “You have four
raw material bins lled with T-shirts. ey are positioned at the four
corners of the room (Figure5.1). You should pick a T-shirt in the closest
raw material bin.” Daniel started the demo:
Once you pick the T-shirt, you should inspect it by checking the quality
of the neckband, and the bond on the sleeve hem and the garment hem
(Figure5.4). en iron the T-shirt in the press. is automated machine
processes in 10 seconds. Once ironing is nished, fold the T-shirt and lay
it in the storage area. When you fold the T-shirt, please make sure that the
logo is visible as in the sample in my hands (Figure5.4). Now I will perform
two more runs; please observe what I am doing and ask questions when
you need to.
Start
buon
Press Made of a Folded Cardboard
1/ The operator loads the press with a t-shirt
2/ The operator closes the press and pushes the start buon
3/ After 10 seconds the press-handler opens the press
FIGURE 5.3
Description of the operation of the ironing press.

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