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Standard work combination table
A standard work combination table shows how one operator's work combines with the machines they run, element by element, on a time chart against takt. Manual work, walking and machine time are drawn in different lines, so it is clear when the operator is working, walking or waiting and when each machine is running on its own. The cycle time is the longer of the operator's loop (manual plus walk) and the longest machine cycle (load plus auto); when a machine needs longer than the loop, the operator waits for it. Page 1 of the PDF is the blank table with takt, operator time, the longest machine cycle and cycle time, a 70-box time chart and columns for manual, auto, walk and wait. Page 2 is a worked example drawn on the chart, a one-operator cell where the mill sets the cycle, with what to check before posting it. Page 3 is a process capacity sheet: how many pieces each machine can make in a shift, including tool changes. The Excel version works out takt, the machine cycles, operator time, cycle time and the wait, the start and end of every element, and draws the chart with machine time carrying past the cycle end, plus a process capacity sheet that finds the machine that limits the cell. The standard work sheet template pairs a simpler combination table with the station layout and standard WIP; this one adds the waits, the machine cycles and the capacity check.
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
When to use it
When to use a combination table
- When one operator runs more than one machine, to see whether the machines are ready when the operator comes back.
- When setting up a cell or rebalancing it after a takt change, to check the operator's loop fits inside takt.
- To find waiting: an operator standing at a machine for its auto cycle to finish.
- Alongside the standard work chart (the layout and path) and the job breakdown, as one of the three standard work documents.
How to fill it in
- 1
Work out takt
Available time per shift in seconds ÷ demand per shift. 27,000 seconds and 450 parts give a takt of 60 s.
- 2
List the work elements in order
One row per element as the operator does it, starting at the same point each cycle. Time each one on the floor several times and use a repeatable time, not the fastest.
- 3
Split each element into manual, auto and walk
Manual is the operator's hands-on time, auto is the machine running on its own after it is started, walk is the time to the next element.
- 4
Draw the chart
Each element starts where the one before it ends: manual as a solid line, walk as a wavy line after it, machine time as a dashed line from the end of the manual work. Draw takt as a red line.
- 5
Check every machine is ready
A machine's load plus auto time must fit inside the operator's loop. If it does not, its dashed line runs past the cycle end and the operator waits; write the wait in.
- 6
Check machine capacity
On the process capacity sheet, work out each machine's pieces per shift with its tool changes. A machine below demand cannot be fixed by moving operator work.
A filled-in example
Illustrative, not a benchmarkA one-operator machining cell (illustrative), the same numbers as on page 2 of the PDF and in the Excel worked example.
- Takt: 27,000 seconds ÷ 450 parts = 60 s.
- Operator time: 38 s of manual work plus 17 s of walking = 55 s.
- Lathe: 8 s to unload and load + 30 s auto = 38 s, ready long before the operator comes back. Mill: 7 + 50 = 57 s, 2 s longer than the operator's loop, so the operator waits 2 s at the mill every cycle.
- Process capacity: the mill's 57 s plus 240 s of tool change every 200 pieces is 58.2 s a piece, and 27,000 ÷ 58.2 = 463 pieces a shift, the lowest in the cell and close to the demand of 450.
Cycle time is 57 s, set by the mill, under the 60 s takt with 3 s to spare. Moving operator work will not shorten it; cutting the mill's auto time or its tool change time will.
Common mistakes
Adding manual and machine time together
Machine time runs while the operator does other work. Only the operator's manual and walk time make up the loop; machine time matters when it is longer than the loop.
Timing from the desk
Use times measured on the floor, several cycles each. Times from routings or estimates leave out the small walks and waits that the chart is meant to show.
Hiding the wait
Waiting for a machine is real time in the cycle. Leave it on the chart where everyone can see it, then work on the machine.
Filling every second up to takt
A loop drawn at exactly takt has no room for a small problem. Leave a little space and use it to see when something goes wrong.
Download the template
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Run this template in LeanSuite
In LeanSuite the AI times each operator's work elements from one video of the line and charts every station against a takt line that recalculates when demand changes, and you drag elements between operators and save each scenario with the minutes and cost it saves.
In the lean glossary
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FAQ
Standard work combination table: common questions
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