ABB Basic Quality Tools Series

Standardization
Setting the basis for quality and continuous
improvement

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 Standardization - Content
What is it for?
It provides the baseline for Quality and Continuous Improvement.
Ensuring that all work and management procedures are done in the
same way
Standardization helps stabilize a process to make it more measurable,
predictable, and controllable
Where could I use it?
In Q4 of an Improvement Project to help to sustain the gains.
For all work and management procedures .
A standard is the end point of one improvement and also the starting point
for the next improvement
How do I use it?
There are 3 categories of methods to standardise the improvement :
Documentation: procedures, instructions, forms must all be
updated/created and any previous versions made unavailable or
destroyed.
Cultural issues: changing/removing/replacing anything that relates to
the previous process. This can include such methods as burning Standardization
bridges, replacing icons such as uniforms, logos or insignia.
Improvement
Visual Management: A system that enables people (even new people Standardization
in the area) to recognise a standard and deviations from that standard
Improvement
Risks and how to avoid them Standardization
Improvement
Example
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 Standardization - What is it for?
Uses of this tool:
Standardization is used to develop consistent processes in all areas of the workplace, which can be
understood by all. It takes the form of documentation, visual management and culture
Standardization provides the starting point for improvement.
With higher levels of standardization, process variation is reduced, which will result in low variation of
the process output. Low variation of the output means improved quality.
Ensuring that all work and management procedures are done in the same way
Standardization helps stabilize a process to make it more measurable, predictable, and controllable
Process standardization is the minimum level of acceptable process maturity

Expected Benefits:
Standardization is an important step towards stability for predictable planning and execution

High levels of standardization, reduce process variation and improve quality.

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 Standardization - Where could I use it?
Background: Uses:
Use it for all work processes and activities
Todays standardization .... is the necessary
where a basis for improvement is desirable:
foundation on which tomorrows improvement
will be based. If you think of standardization
Production
as the best you know today, but which is to
Installation
be improved tomorrow - you get somewhere.
Project bidding
But if you think of standards as confining,
Maintenance
then progress stops Henry Ford Today &
Material management
Tomorrow, 1926
Performance Appraisal
Taicho Ohno established the principle that Planning
standardization was the key ingredient to Marketing
allowing one piece flow and JIT production Service
Compliance
Deming proposed a PDCA (Plan Do Check
Continuous Improvement
Act) cycle, seeing improvement as moving
HR
from standard to standard.
Juran emphasised the point of holding the
gains of improvements

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 Standardization - How do I use it?
Procedure and Guidance Notes:
Identify key activities / steps and classify List activities and sort out frequently repeated
Understand the activities from irregular activities. Standardise
process activities the repeaters and sort out the irregular activities
into blocks (e.g. fetching parts regularly).

Establish a Clear Objective for the standard Remember that standard ways of working can
Consider Standards include things which should not be done (e.g.
for each step Health & safety) as well part of the optimum
ways of working.

Develop standard optimum ways of working, detailing What Who Best practice is for those performing the task to
Develop Standard When Where & How and agreeing with the team write their own standards.. It may be that they
using Criteria are assisted in the task by Industrial Engineers.
Accurate - Use objective words to describe the standard. Subjective
This ensures 1. That Standards are understood
words such as careful and frequently should be avoided.
2. That workers are forced to think about the
Quantify - The standard should be easy to understand. To achieve this, best way to perform a task 3. Responsibility
photographs, drawings, figures and charts should be used as much as remains with the operator 4. Standards reflect
possible. what actually happens and support training and
job changes.
Practical -The standards describes how the work must be done. It Remember that standards can be in the form of
should be practical in the current situation, and not represent an ideal documentation (e.g. standard instructions
future situation. and/or visual management tools)

Put standards in place with full team involvement.

Implement

Revisions - The standard should be revised if necessary as part of the Ensure that the standard is configured (with
Review & update Plan Do Check Act improvement loop. Because the work is done issue & release date) and has an owner.
according to standard, the standard must reflect the current best
solution.

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 Standardization - How do I use it?
As a basis for Continuous Standardization
Improvement Improvement

Standardization

Improvement

Standardization

Improvement

Processes with less variation have

less defects.
LSL USL The concept of defect reduction
applies to ALL processes (not just
manufacturing)
High
High Variation
Level of variation

High Potential
Defects
Unpredictable
As a way of reducing Quality LSL USL

process variation
Low Variation
Low Level of standardization High Low Potential
Defects
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 Standardization - Risks and how to avoid them:
Risks : Steps to avoid them :
Misunderstanding of Standardized Instructions leading Instructions should define Who should do What by
to process variation Which method at Which frequency to achieve Which
level; Pictures helps a lot to achieve the common
understanding among different people.

Standardization is interpreted as imposing standards on

Standards are developed by the team for the team to
operators no buy in, no basis for improvement and
develop ownership and reflect the real situation.
large process variance.
Standards are too tight rigid, tedious and bureaucratic
Consideration is given to the method and format of
Standards are too loose variation, ineffective and
standardization to balance the risk of too tight vs.
inefficient
too loose.

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 Standardization - Examples
Maintenance
Employee Performance Appraisal

Quality

Project Management (PA)

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 Standardization - Example

1. Define a clear objective

5. Review & Update

Include Revision details,

Owner and Date

4. Accurate
2. Quantify
The standard
The standard should be should be
specific & easy to accurate to any
understand technical specs
e.g. drawings

3. Practical
The standards describes how the
work must be done. It should be
practical & current . Photographs,
drawings, figures and charts should
be used as much as possible..
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