SOP writing course supplement
Employee Training and Development with Standard Operating Procedures
Third Edition
By Mike Sondalini
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 a 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 when used properly, they will maximize 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, and most certain way to successfully train and develop employees to deliver world-class quality and performance. Realize and release the continuous improvement power of Standard Operating Procedures across your organization.
Third Edition: This edition expands on the 3T failure prevention method and adds more diagrams.
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 lay out SOPs horizontally for Value Stream Mapping to drive continual 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. It is much simpler than establishing a quality management system like the ISO9000 series. An ACE uses a 3T failure prevention methodology as an enterprise development tool.
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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) ................................................... 10319.5. 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.).......................................................................... 10519.8. Be Simple, Be Exact
(Clearly indicate every action, measure and timing) ...................................... 10619.9. 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
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