Employee Training and Development with SOP eBook - 2nd Edition by Mike Sondalini
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How to incorporate failure prevention, kaizen training, value stream mapping training and other enterprise development tools into your SOP development. With this Standard Operating Procedures example you can develop a world class manufacturing SOP template.
This second edition has a new development to encourage the rapid creation of high skills and abilities through enterprise development. It is called the '3T failure prevention method' - 3T stands for 'Target, Tolerance and Test'. You will learn how to use 3T failure prevention during SOP development so that work quality skyrockets as people quickly become highly skilled. Another new method used in the second edition is a revised way to layout SOPs horizontally for Value Stream Mapping to continuous improvement model for job performance by indentifying wasted time and resources.
The last major inclusion in this edition is to present the simplest enterprise quality performance improvement program known. The 'Accuracy Controlled Enterprise', or ACE, represents an ideal to strive for in running organisations. Much simpler than establishing a quality management system like the ISO9000 series, or introducing Lean or Six Sigma. An ACE uses 3T failure prevention methodology as an enterprise development tool.
"In reality SOPs should be written to save organisations time, money, people and effort because, used properly, they will maximise productivity and deliver outstandingly reliable performance every time. Remember, a business that does not pursue excellence in all activities will not last; those that do always prosper".
Make your SOPs the finest, fastest, most certain way to successfully train and develop employees to deliver world-class quality and performance. Realise and release across your organisation the continuous improvement power of Standard Operating Procedures.
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Table of contents
- 1. A clear path to world-class performance and results
- 1.1 The bus trip
- 1.2 Business processes should always deliver right results
- 1.3 The accuracy controlled enterprise: prevent human error everywhere, every time
- 3. Purpose of standard operating procedures
- 3.1 The cost of poorly written standard operating procedures
- 3.2 Human error rates
- 4. The accuracy controlled enterprise concept (what it means to be an ACE)
- 4.1 Hold your ground
- 5. Building reliable work process processes and systems
- 5.1 Series systems
- 5.2 Parallel systems
- 6. Variability in outcomes
- 6.1 Spotting variability
- Example 6.1: Inventory Replenishment Mayhem
- Example 6.2: Seeing variability - the cross-hair game
- 7. Controlling variability
- 7.1 Variability causes defects and failures
- 7.2 Why failures happen
- 8. The ACE uses SOPs to prevent defects and failures at all levels
- 8.1 Controlling accuracy - removing error
- 8.2 Accuracy control - the purpose of targets in SOPs
- 8.3 The need for tolerances in procedures
- 8.4 The way the accuracy controlled enterprise uses SOPs
- 8.5 Further reducing the effects of variation
- 8.6 Becoming an ACE starts from the top
- 9. Developing ACE procedures
- 9.1 Easily definable standards and measures
- 9.2 Difficult to define standards and measures
- 9.3 Handling procedural non-conformances
- 10. Extra benefits of being an ACE
- 10.1 Far fewer downstream problems
- 10.2 Less expensive inspections
- 10.3 Better, faster training in-built
- 10.4 Less highly skilled employees needed for less cost
- 11. Raising standards - intentionally improving skills
- 11.1 Systematise the learning process
- 11.2 Develop training plans for each person
- 11.3 The importance of raising standards
- 12. The cost of poorly written standard operating procedures
- 12.1 The best SOPs can be done by the least skilled people
- 12.2 Train and retrain your people to your standard operating procedures
- 12.3 The focus becomes improving the system performance
- 13. The power of visual control measures
- 13.1 Visual control measures for continuous processes
- 14. The curse of being average
- 14.1 Understanding elite performers in population distributions
- 14.2 The curse of being an average business
- 14.3 Getting more than average performances
- 14.4 Why teams outperform
- 14.5 Implications for managing organisations
- 15.1 Importance of standardisation when seeking to be an ACE, Lean or Six Sigma
- 16. When not to use a SOP
- 17. A story of the success and power of a SOP
- 18. The secret of writing a successful SOP
- 19. Writing a 3T failure prevention SOP
- 19.1 SOPs are powerful preventive action
- 19.2 The best person to write an SOP
- 19.3 SOP for teams
- 19.4 Layout to aid understanding (make it intuitively easy to absorb)
- 19.5 Starts with a summary, end with the facts
- 19.6 List all tool, equipment and references
- 19.7 Be totally complete (don't only write it, show it)
- 19.8 Be simple, be exact (clearly indicate every action, measure and timing)
- 19.9 Full details clearly provided step by step
- 19.10 Provide regular self testing for certainty
- 19.11 Request proof that each step is done correctly
- 19.12 Keep it a true record of current best practices
- 19.13 Keep control of the documents and records
- 19.14 Keep the master copy safe
- 20. SOP using value stream mapping kaizen layout
- 20.1 Value stream mapping overview
- 20.2 Investigation
- 20.3 Analysis
- 20.4 Identifying improvements
- 20.5 Using VSM for SOP continuous improvements and preventive action
- 20.6 Benefits of using horizontal value stream mapping kaizen layout
- Example 20.1: VSM kaizen SOP horizontal layout
- 21. Conducting training
- 22. Conduct random audits
- 23. Example - shoe lace tying
- 24. Example - cash flow spreadsheet
- 25. Example - flange connection 3T failure prevention SOP with tolerance banding
- 26. Epilogue
- 27. On the importance of doing a job well
- 27.1 What are standards?
- 27.2 Setting competency standards
- 27.3 The power of a quality management system
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