First steps
- Pick the best shift’s method.
- Write it with the operators.
- Train, audit and improve it.
How to measure success
LPA score and variation between shifts. Record the value before you start, so the effect of every action can be shown.
When these methods are the wrong choice
- Standard work / work instruction: Processes that are still changing every week.
- Layered process audit (LPA): Finding root causes.
- 5S: Process capability problems.
- Skill matrix and training: Problems that occur with qualified, experienced people.
- Turtle diagram: Product defects.
The methods in one line
| Method | What it is |
|---|---|
| Standard work / work instruction | The current best way to do a job, with key points and reasons, used for training and audits. |
| Layered process audit (LPA) | Short daily checks of key process controls by several management layers. |
| 5S | Workplace organisation: sort, set in order, shine, standardise, sustain. |
| Skill matrix and training | Shows who is qualified for which job and plans training before people are needed. |
| Turtle diagram | Describes one process with inputs, outputs, resources, people, methods and KPIs. |