6 min read

How to Reduce Changeover Time with Standard Work Instructions

By Dozuki

Many manufacturers see reducing changeover time as a golden opportunity to improve operational efficiency and reduce waste. For good reason, a simple reduction in changeover time can increase output, reduce inventory/WIP, and improve responsiveness to customer demand.

Topics: Standard Work Work Instructions
6 min read

What's Wrong with Standard Work?

By Dozuki

66% of companies fail in their attempts at Standard Work.

Topics: Standard Work
2 min read

Free Standard Operating Procedure & Work Instruction Templates

By Dozuki

Standard operating procedure (SOP) and work instruction templates help standardize processes and present information consistently. We’ve seen thousands of examples of these templates and the only consistency is their shortcomings. 

Topics: Standard Work Work Instructions
4 min read

What is Standard Work?

By Dozuki

Lean operations and manufacturers have used Standard Work for decades, yet many companies lack clarity when it comes to this fundamental lean methodology.

Topics: Continuous Improvement Standard Work
3 min read

How to Establish a Lean Culture in 4 Steps

By Leslie Bloom

An effective lean culture aims to reduce waste and inefficiency while improving the value delivered to customers. The lean organization is a model that’s been historically applied to manufacturing, but many of the principles have something to offer businesses across a wide range of industries.

Topics: Continuous Improvement Standard Work
5 min read

Kaizen and Standardization with Dr. Robert Maurer

By Dozuki

We spoke with Dr. Robert Maurer, author of “Spirit of Kaizen,” a leading expert in the field of psychology and organizational change, about Kaizen and the role of standardization in improving processes and creating an efficient culture of continuous improvement.

Topics: Continuous Improvement Standard Work Book Club Series
4 min read

11 Benefits of Standard Work

By Dozuki

Taiichi Ohno, a founder of the Toyota Production System (TPS), had this to say about Standard Work, “without standards, there can be no Kaizen.” As the foundation for all lean, six sigma, and continuous improvement efforts, the benefits of Standard Work are endless. Ohno's wisdom speaks volumes to the importance of Standard Work, yet many companies aren’t fully practicing it.

Topics: Standard Work
4 min read

Inside the Mind of an ISO Auditor

By Dozuki

062518-InsideMind-ISOAuditor-01-1-e1529694203468-272x300Getting inside the mind of an ISO 9001 auditor is crucial to a successful ISO audit. Think of it like a gift — even the best of presents can be unappealing when wrapped in crumpled messy newspaper and duct tape.  

Topics: Quality Standard Work
4 min read

Embracing Waste in a Lean Culture

By Dozuki

These days, waste gets a bad rap.

‘Eliminating waste’ is such a common phrase among lean and six sigma practitioners, the two words are practically inseparable. The problem with this marriage is that it causes us to conflate all types of waste as equally harmful.

Topics: Continuous Improvement Standard Work
4 min read

In Conversation with John Allwood

By Dozuki

Topics: Standard Work Book Club Series
3 min read

Vienna Sausage: A Story of Standards and Tribal Knowledge

By Dozuki

Imagine that you lost the ability to make your key product.

What if your core revenue driver was suddenly different...

And you didn't know why.

We recently came across a radio segment that outlined a similar problem that Chicago-based Vienna Beef had with their hot dog production. After the company made the transition to a new production facility, their staple product changed — and nobody knew why.

Topics: Standard Work Industry News
4 min read

How to Perform a Time Observation

By Dozuki

Without Standard Work, documented processes are often not used, or so out of date, that following them could become problematic. Standard Work is the foundation for any continuous improvement or Lean program, and time observations are the starting point. They are the foundation for which improvements are based on.

Topics: Standard Work
1 min read

Top 10 Shigeo Shingo Quotes on Lean Manufacturing

By Dozuki

Shigeo Singo: The Ambassador of Lean

Shigeo Shingo was an industry leader of Lean manufacturing principles and philosophies. Originally brought on by Toyota to update their Training within Industry (TWI) coursework and later assisting in improving changeover times, Shigeo used his experience with the Toyota Production System to write several books, both in Japan and the United States. His work promoting Lean principles in the West is what he is most known for today.

Topics: Standard Work Industry News
3 min read

Navigating Processes: Standard Work vs. Work Instructions

By Dozuki

The manufacturing industry is a professional arena with an overwhelming variety of industry terms and acronyms. We’ve tried to make a list of the most common Lean terms before… we didn’t get very far.

Topics: Continuous Improvement Standard Work Work Instructions
3 min read

Why Standard Work is a Contradiction

By Dozuki

030218-StandardWork-Contradiction-01We recently wrote a popular article about a major mistake at a nuclear waste facility. In short, we cited poor standard revision processes as the root cause of the mistake, costing the company $500 million to remediate.

Topics: Continuous Improvement Standard Work Industry News
2 min read

Implementing Continuous Improvement with Dozuki

By Dozuki

Is your company interested in reaping the benefits of continuous improvement (transparency, efficiency, cost reductions, etc.) but aren't sure where to begin? Dozuki has you covered.

Topics: Continuous Improvement Standard Work Digital Transformation Workforce Training
4 min read

What Caused the False Missile Alert in Hawaii

By Dozuki

Apparently, it was a simple mistake that caused the false missile alert to be sent to phones across the state of Hawaii. And while citizens were still recovering from the disorienting news, media outlets were quick to place blame. 

Topics: Standard Work Industry News
3 min read

Hidden Waste: The Unseen Inefficiency in Shop Travelers

By Brian Sallee

Travelers and build books are intimately related, however, with traditional methods they often function independently.

Topics: Product Standard Work Digital Transformation
3 min read

The Ultimate Lean Glossary

By Dozuki

The world of Lean Manufacturing is full of acronyms and industry buzzwords. No glossary could encompass the full breadth of terminology, but it’s always helpful to have a consolidated resource to use as a reference.

Topics: Continuous Improvement Standard Work
4 min read

Got Standards? The Million Dollar Grammar Mistake

By Dozuki

Maine based Oakhurst Dairy was recently sued by a handful of truck drivers seeking more than four years worth of overtime pay—but the suit wasn’t about milk distribution at all. Rather, the legal battle revolved around the use (or lack thereof) of a single comma. But grammar wasn’t the problem—standards were.

Topics: Standard Work Industry News Technical Writing Workforce Training
2 min read

Skip the Busy Work and Focus on Improving

By Dozuki

Whether you’re implementing new software or a new machine on the factory floor, continuous improvement projects take time to get set up before they, well…improve things.

Topics: Standard Work Technical Writing
3 min read

Millennials, Vinyls, and Documentation

By Dozuki

Vinyl is in the midst of a comeback. Perhaps it’s due to the unpredictable whims of Millennial trends. Or, perhaps it’s the byproduct of a digital backlash from consumers who want to own their music, rather than paying for a Spotify subscription. Either way, record sales are increasing, and manufacturers are struggling to step up to the challenge.

Topics: Standard Work Workforce Training
5 min read

Lean Startups Need to Start Documenting to Scale

By Dozuki

For startups that have begun to establish themselves as a sustainable business, growing pains are only a matter of time.

Topics: Standard Work Workforce Training
3 min read

How Sloppy Revision Control Cost WIPP Half a Billion Dollars

By Dozuki

Revision process causes extreme damage and financial lossesIn 2014 a nuclear Waste Isolation Pilot Plant (WIPP) in Carlsbad, NM was the victim of poor revision control practices that lead to a half-billion dollar mistake; shutting down the facility for three years and sending six workers to the hospital.

Topics: Quality Standard Work Industry News Workforce Training
5 min read

Upgrading Processes with Continuous Improvement

By Dozuki

Many companies implement formal versions of Lean or Agile methods, but others have grown with the flexibility that continuous improvement provides, giving them the freedom to deviate from the formal approaches of Lean/Agile methods when needed.

Topics: Continuous Improvement Standard Work Customer Stories Digital Transformation
1 min read

Electronic Work Instructions for Field Technicians

By Leslie Bloom

 

Topics: Standard Work Customer Stories Work Instructions
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