Failure prevention in SOP development, enterprise development

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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 Procedures

Third Edition

By Mike Sondalini

How to incorporate failure prevention, kaizen training, value stream mapping training into SOP development.

Standard Operating Procedures example - Contents

Employee Training and Development with Standard Operating Procedures Ebook - Third Edition
ISBN: 978-0-9750232-4-2
Description:  

How to incorporate failure prevention, kaizen training, value stream mapping training and other enterprise development tools into your SOP development. With this Standard Operating Procedures example you can develop a world class manufacturing SOP template.

This third edition has a new development to encourage the rapid creation of high skills and abilities through enterprise development. It is called the ‘3T failure prevention method’ – 3T stands for ‘Target, Tolerance and Test’. You will learn how to use 3T failure prevention during SOP development so that work quality skyrockets as people quickly become highly skilled. Another new method used in this second edition is a revised way to layout SOPs horizontally for Value Stream Mapping to continuous improvement model for job performance by identifying wasted time and resources.

The last major inclusion in this edition is to present the simplest enterprise quality performance improvement program known. 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

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.

Email with download link sent immediately after purchase.

Price:  US$29.95 (187 pages)

Shop More

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?

 

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Table of Contents

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 (131 pages)

Shop More

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.

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 Procedures

Third Edition

By Mike Sondalini

How to incorporate failure prevention, kaizen training, value stream mapping training into SOP development.

Standard Operating Procedures example - Contents

Employee Training and Development with Standard Operating Procedures Ebook - Third Edition
ISBN: 978-0-9750232-4-2
Description:  

How to incorporate failure prevention, kaizen training, value stream mapping training and other enterprise development tools into your SOP development. With this Standard Operating Procedures example you can develop a world class manufacturing SOP template.

This third edition has a new development to encourage the rapid creation of high skills and abilities through enterprise development. It is called the ‘3T failure prevention method’ – 3T stands for ‘Target, Tolerance and Test’. You will learn how to use 3T failure prevention during SOP development so that work quality skyrockets as people quickly become highly skilled. Another new method used in this second edition is a revised way to layout SOPs horizontally for Value Stream Mapping to continuous improvement model for job performance by identifying wasted time and resources.

The last major inclusion in this edition is to present the simplest enterprise quality performance improvement program known. 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

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.

Email with download link sent immediately after purchase.

Price:  US$29.95 (187 pages)

Shop More

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?

 

Industrial manufacturing services provider you can trust.

 


Table of Contents

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

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

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 ....

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 ....

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)

Shop More

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.

Up
MORE MANAGEMENT
Business Engineering
Maintenance Policies 2
Total Productive Maintenance PPT
Maintenance Reliability PowerPoints
EAM Systems PowerPoints
Planning & Scheduling Powerpoint
SOP development - 2
Process Risk Management
Engineering Project Management
System Engineering Reports
Business Report Writing
Project Management Reports
Accuracy Controlled Enterprise
Defect - Failure True Cost
True Downtime Cost Analysis 2
Operational Intg. Management
Work Order System
Total Quality Management
Emergency Power Plan
Facility Management
Maintenance Policy ...
Asset Management Toolkit
Writing SOP
Process Hazards Analysis
Process Safety Audit
Performance Based Safety
Fault Tree Analysis
Criticality Analysis
Lean Manufacturing
Maintenance Advisor
Key Performance Indicator
Maintenance Excellence
CMMS Advice
CMMS Selection Kit
CMMS Insider's Guide
Silver Reliability Training
Gold Reliability Training
In House Training
Maintenance Bible
Asset Management
Ebooks on CD
Maintenance Planning CD
SOP Training
Project Management Training
Inventory Control CBT

 

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