Does the 'usual way of doing things' hinder company growth? Successful examples of standardization.
Manufacturing Industry New Employee Training: Task specialization leads to a decline in productivity and quality! Standardization serves as the foundation for supporting corporate growth.
In manufacturing sites, there is often a deeply rooted "usual way of doing things" based on years of experience. However, such personalized work methods can lead to issues such as difficulties in training new employees, variations in quality, and inefficiencies in operations. In particular, when experienced workers retire or transfer, it becomes difficult to pass on their skills, which can hinder the growth of the company. Reliance on personalized work methods tied to the "usual way of doing things" can become a barrier to corporate growth. By promoting the standardization of work processes, improvements in quality, efficiency in training, and increased productivity can be achieved, thereby enhancing the overall competitiveness of the company. Standardization is a foundational initiative that supports sustainable growth. *For more details, please feel free to contact us.*
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Proposal for Solutions: Improving Quality and Efficiency through Standardization of Work Standardization of work is an initiative to eliminate dependency on individuals, allowing everyone to perform tasks using the same procedures. This is expected to yield the following effects: ● Uniformity of Quality: By standardizing work procedures, the quality of products becomes stable. ● Efficiency of Training: Training for newcomers and transfers becomes smoother, allowing for a reduction in the training period. ● Efficiency of Operations: Redundant tasks and rework decrease, leading to increased productivity. ● Succession of Skills: The know-how of experienced workers is accumulated as explicit knowledge and can be shared across the organization.
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Implementation Steps: How Companies Should Proceed STEP 1: Understanding Current Work Procedures Observe the work procedures on-site and identify areas that are overly dependent on specific individuals and points for improvement. STEP 2: Creation of Standard Operating Procedures Record the work of experienced personnel on video and document it as a procedure manual. Use diagrams and photos as needed to make it visually clear. STEP 3: Integration into Training Programs and Continuous Improvement Incorporate the created procedure manual into training programs and use it for training new employees and those transferring to different roles. Additionally, conduct regular reviews to keep the content of the manual up to date.
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P3
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OTHER
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Custom-made training video
Applications/Examples of results
Introduction of a Success Case: A Company That Reduced Defect Rate by 30% Through Standardization of Work Processes In a mid-sized manufacturing company, work procedures were left to individual workers, leading to variations in quality and inefficiencies in training. To address these issues, the following initiatives were implemented: ● Visualization of Work Procedures: Recorded the work of skilled workers on video and created standard operating procedure manuals. ● Development of Training Programs: Introduced training for new employees using video materials. ● Regular Reviews: Conducted periodic reviews and improvements of work procedures. As a result of these measures, the defect rate decreased by approximately 30%, and the training period was shortened to half of the previous duration. Additionally, information sharing among workers became more active, and communication on the shop floor improved.
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| Model number | overview |
|---|---|
| Points to Consider for Successful Standardization 1️⃣ | Incorporate Field Opinions: By creating procedures that reflect the opinions of workers, the effectiveness in the field is enhanced. |
| Points to Consider for Successful Standardization 2️⃣ | Continuous Improvement: Standard operating procedures are not a one-time creation; regular reviews and improvements are necessary. |
| Points to Consider for Successful Standardization 3️⃣ | Collaboration with Education: By incorporating standardized procedures into training programs, it becomes possible to quickly develop new employees into effective contributors. |
| Points to Consider for Successful Standardization 4️⃣ | Management Involvement: When management understands the importance of standardization and actively engages, it becomes a company-wide initiative. |
