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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