First steps
- Build the skill matrix per line.
- Train against work instructions.
- Certify before solo work.
How to measure success
Defects by operator tenure and skill coverage. Record the value before you start, so the effect of every action can be shown.
When these methods are the wrong choice
- Skill matrix and training: Problems that occur with qualified, experienced people.
- Standard work / work instruction: Processes that are still changing every week.
- Layered process audit (LPA): Finding root causes.
- Poka-yoke: Causes in the material or the supplier’s process.
The methods in one line
| Method | What it is |
|---|---|
| Skill matrix and training | Shows who is qualified for which job and plans training before people are needed. |
| 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. |
| Poka-yoke | Makes the error impossible or detects it immediately, so it does not depend on attention. |