Industrial Training - The Best for Less

Employee Training and Development with Standard Operating Procedures

Third Edition

By Mike Sondalini

 

Enterprise Development Tool - SOP writing, SOP training

Ebook: Standard Operating Procedures examples - Contents

Employee Training and Development with Standard Operating Procedures Ebook 

- Third Edition 

ISBN: 978-0-9750232-4-2
Description:  

Create an accuracy controlled enterprise development tool using SOP writing and SOP training. Stop errors with 3T failure prevention methodology and use a value stream map Kaizen format for continuous improvement.

 

In reality SOPs should be written to save organizations time, money, people and effort because, used properly, they will maximize productivity and deliver outstandingly reliable performance every time. Remember, a business that does not purse 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. Realize and release across your organization the continuous improvement power of Standard Operating Procedures.

 

Third Edition: Expands on 3T failure prevention method and VSM Kaizen SOP Layout! More diagrams add too.

The expansion of 3T methods and new diagrams further increase the rapid creation of high skills and abilities throughout an organization. It is called the ‘3T failure prevention method’ – 3T stands for ‘Target, Tolerance and Test’. You will learn how to incorporate it into SOPs so that work quality skyrockets as people quickly become highly skilled. Another addition worthy of mention is a revised way to layout SOPs horizontally for Value Stream Mapping to drive continually improvement in job performance by identifying wasted time and resources.

 

The Accuracy Controlled Enterprise, or ACE, represents an ideal to strive for in running organizations. Much simpler than establishing a quality management system like the ISO9000 series. An ACE uses 3T failure prevention methodology as an enterprise development tool

 

About the Author ...

Although you might recognize author Mike Sondalini from his many mechanical engineering related books published in the last decade, Mike also has many industrial management books published. His management books published take on the same style of being real world, practical and easy to read and focused on enterprise development. The author's approach is for his books to be applicable to all businesses, not just the industrial sector. Please see 'Related Titles' at the end of this page for other titles that make great enterprise development tools.

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Price:  US$29.95  (187 Pages)

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Table of Contents

Preface to the Third Edition

Preface to the Second Edition
Preface to the First Edition

1. A Clear Path to World-Class Performance and Results 

1.1. The Journey to World Class Quality ................................................................................................... 10

1.2. A Bus Trip Analogy ............................................................................................................................ 13

1.3. Business Processes Should Always Deliver Right Results ................................................................. 19

1.4. The Carpenter‘s Creed: ―Measure twice, cut once. ........................................................................... 20

1.5. Two-Sided Performance Limits—How Accurately do You Set Your Clocks? .................................. 21

1.6. The Accuracy Controlled Enterprise and the 3T Concept .................................................................. 22

1.7. The Accuracy Controlled Enterprise: Prevent Human Error Everywhere, Every Time ..................... 25

1.8. Aim to be an Expert ............................................................................................................................ 27

1.9. The Power of Checklists ..................................................................................................................... 29

2. ACE 3T Mistake Proofing Optimizes Taguchi Loss Functions

3. Purpose of Standard Operating Procedures 

3.1. The Cost of Poorly Written Standard Operating Procedures .............................................................. 36

3.2. Human Error Rates ............................................................................................................................. 37

4. The Accuracy Controlled Enterprise Concept (What it means to be an ACE.)

4.1. Hold Your Ground .............................................................................................................................. 40

5. Building Reliable Work Processes and Systems

5.1. Series Systems .................................................................................................................................. 41

5.2. Parallel Systems ................................................................................................................................ 44

6. Variability in Outcomes

6.1. Spotting Variability ............................................................................................................................. 46

Example 6.1: Inventory Replenishment Mayhem .............................................................................................. 47

Example 6.2: Seeing Variability - The Cross-Hair Game .................................................................................. 50

7. Controlling Variability

7.1. Variability Causes Defects and Failures ............................................................................................. 56

7.2. Why Failures Happen ......................................................................................................................... 60

8. The ACE uses SOPs to Prevent Defects and Failures at All Levels 

8.1. Controlling Accuracy – Removing Error ............................................................................................ 62

8.2. Accuracy Control – The Purpose of Targets in SOPs ......................................................................... 64

8.3. The Need for Tolerances in Procedures .............................................................................................. 65

8.4. The Way the Accuracy Controlled Enterprise Uses SOPs .................................................................. 66

8.5. Further Reducing the Effects of Variation .......................................................................................... 68

8.6. Becoming an ACE Starts from the Top .............................................................................................. 70

9. Developing ACE Procedures

9.1. Easily Definable Standards and Measures .......................................................................................... 72

9.2. Difficult to Define Standards and Measures ....................................................................................... 72

9.3. Handling Procedural Non-Conformances ........................................................................................... 73

10. Extra Benefits of Being an ACE

10.1. Far Fewer Downstream Problems ....................................................................................................... 74

10.2. Less Expensive Inspections ................................................................................................................ 75

10.3. Better, Faster Training In-built ........................................................................................................... 75

10.4. Less Highly Skilled Employees Needed for Less Cost ....................................................................... 75

11. Raising Standards - Intentionally Improving Skills

11.1. Systematize the Learning Process ....................................................................................................... 77

11.2. Develop Training Plans for Each Person ............................................................................................ 78

11.3. The Importance of Raising Standards ................................................................................................. 78

12. The Cost of Poorly Written Standard Operating Procedures

12.1. The Best SOPs Can Be Done By the Least Skilled People. ................................................................ 80

12.2. Train and Retrain Your People to Your Standard Operating Procedures ........................................... 81

12.3. The Focus becomes Improving System Performance ......................................................................... 82 4

13. The Power of Visual Control Measures

13.1. Visual Control Measures for Continuous Processes ........................................................................... 84

14. The Curse of Being Average 

14.1. Understanding Elite Performers in Population Distributions .............................................................. 85

14.2. The Curse of Being an Average Business ........................................................................................... 88

14.3. Getting More than Average Performance ........................................................................................... 89

14.4. Why Teams Outperform ..................................................................................................................... 91

14.5. Implications for Managing Organizations .......................................................................................... 92

15. When to Use a 3T SOP

15.1. Importance of Standardization when Seeking to be an ACE, Lean or Six Sigma .............................. 93

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 .............................................................................................. 101

19.2. The Best Person to Write an SOP ..................................................................................................... 101

19.3. SOP for Teams ................................................................................................................................ 103

19.4. Layout to Aid Understanding (Make it intuitively easy to absorb) ................................................... 103

19.5. Start With a Summary, End with the Facts ....................................................................................... 104

19.6. List all Tools, Equipment and References ........................................................................................ 105

19.7. Be Totally Complete (Don't only write it, show it.).......................................................................... 105

19.8. Be Simple, Be Exact (Clearly indicate every action, measure and timing) ...................................... 106

19.9. Full Details Clearly Provided Step by Step ....................................................................................... 106

19.10. Provide Regular Self-Testing For Certainty ..................................................................................... 107

19.11. Request Proof That Each Step is Done Correctly ............................................................................. 108

19.12. Keep It a True Record of Current Best Practices .............................................................................. 109

19.13. Keep Control of the Documents and Records ................................................................................... 109

19.14. Keep the Master Copy Safe .............................................................................................................. 109

20. SOP Using Value Stream Mapping Kaizen Layout 

20.1. Value Stream Mapping Overview ..................................................................................................... 111

20.2. Investigation.................................................................................................................................... 113

20.3. Analysis .......................................................................................................................................... 114

20.4. Identifying Improvements ................................................................................................................. 115

20.5. Using VSM for SOP Continuous improvement and Preventive Action ........................................... 115

20.6. Benefits of Using Horizontal Value Steam Mapping Kaizen Layout ............................................... 117

Example 20.1: VSM Kaizen SOP Horizontal Layout ....................................................................................... 119

21. Conducting Training

22. Conduct Random Audits 

23. Example 1 – Shoe Lace Tying

24. Example 2 – Cash flow Spreadsheet

25. Example 3 – Flange Connection 3T Failure Prevention SOP with Tolerance Banding 

26. Example 4 – Install taper spherical roller bearings on adaptor sleeves 

27. Epilogue

28. On The Importance of Doing A Job Well

28.1. What are Standards? ......................................................................................................................... 166

28.2. Setting Competency Standards ......................................................................................................... 168

28.3. The Power of a Quality Management System ................................................................................... 168

29. Creating Procedures and Check Sheets that Improve Reliability 

Bibliography

Index

 

 

 Price:  US$29.95 

 

Shop More

Automated download system is powered by our preferred method of payment, secure Pay Pal.  (After purchase with 'Add to Cart' button above, you immediately receive an email with download link.) If you prefer us to manually process your order or would like to mail or fax order in, please click CD and Book Order Form on our secure servers.

Click for manual order processing, all countries.

(Click on Credit card picture above for manual order processing. Your download link will be emailed within 24 hours with manual processing.)

Related Titles: 

"Maintenance Policy and Procedures Manual"

"Operating Procedures for Process Plants"

"Defect and Failure True Cost"

"The True Downtime cost analysis - 2nd edition"

 

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