6 min read

How to Reduce Changeover Time with Standard Work Instructions

By Corey Brown

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 Corey Brown

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

Topics: Standard Work
2 min read

Free Standard Operating Procedure & Work Instruction Templates

By Corey Brown

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 Corey Brown

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 Corey Brown

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
3 min read

11 Benefits of Standard Work

By Corey Brown

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 Corey Brown

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 Corey Brown

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 Corey Brown

Topics: Standard Work Book Club Series
3 min read

Vienna Sausage: A Story of Standards and Tribal Knowledge

By Corey Brown

Last week we came across a radio segment that outlined an interesting problem that Chicago-based Vienna Beef had with hot dog production. When the company made the transition to a new production facility, their staple product changed — and nobody knew why.

Topics: Standard Work Industry News
3 min read

How to Perform a Time Observation

By Corey Brown

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 Corey Brown

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 Corey Brown

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 Corey Brown

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 Corey Brown

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 Corey Brown

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 Corey Brown

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 Corey Brown

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