Failure prevention in SOP development, enterprise
development
|
|
|
|
|
How to incorporate failure prevention, kaizen training, value stream mapping training and other enterprise development tool into your SOP writing.Employee Training and Development with Standard Operating ProceduresThird Edition By Mike Sondalini
Standard Operating Procedures example - Contents
Automated download system is powered by our preferred method of payment, secure Pay Pal. (After purchase with 'Buy Now' 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 at BIN95.
(Click on Credit card picture above for manual order processing. Your download link will be emailed within 24 hours with manual processing.) What is an 'Ebook'? - Why Buy Ebooks?
Table of ContentsPreface to the Second 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 (131 pages)
Automated download system is powered by our preferred method of payment, secure Pay Pal. (After purchase with 'Buy Now' 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 at BIN95. |
||||||||
|
