In all of my lean journeys or
implementations the use of standard work is often down played or overlooked.
This relatively easy concept is very critical to ensure on-going success,
quality processes, and continual improvement.
Standard work contains four elements- Content, sequence, timing and
outcome. It should define what steps are
taken, when they are taken, how long each step will take and the expected
outcome from these steps. Adding
pictures is very effective when creating standard work. While the manufacturing floor is often the
easiest to document, the largest gains are made in the office setting. These documents help remove the tribal
knowledge that gets built up over time and create and manage pull process in
the office. Some nontraditional examples
include pilots’ checklist, providing quotes to customers, requesting quotes
from supplier, and order entry forms/drop downs.
There are several reasons on why this would be passed over
or not documented.
The first reason is typically lack of time. It’s our wiring that wants us to move onto the
larger issues and work on the next task rather than completing those that can
be seen as non-critical. During an
improvement event it is critical to take the added time and fully document the
processes that will make up the business’ standard work. This will ensure that
months down the road future state plans are still being followed.
The second reason for skipping standard work is lack of
understanding. I’ve seen several situations that only a couple people will be
following the new process so the step gets skipped altogether. Again, while the
day to day users don’t need the standard work document it’s a good reference
for auditing later and/or training purposes. This document acts as a basis for
all future improvements. Once it’s time
to come back and revisit the process you’ll already have a good jumping off
point to start future improvements.
The final reason that we skip standard work is fear. This is most common in an office setting. Some employees fear that if they share the
exact details that they’ll be either given more work or are replaceable. As you tackle your lean journey, you’ll want
to ensure that people’s fears are removed.
The goal should be to free up time with the use of standard work to have
them working on different things that bring more value to the customer.
The use of standard work will only benefit your
business. While it may feel like a
daunting task, just start with one area or process each week and document the
process. Over time, your database will
begin to grow and you’ll have a solid foundation for driving improvements as
the business grows.