Free toolsStability self-assessment

How stable is your process?

Twelve statements, about three minutes. Answer for one product line or cell, as it runs today rather than as it should. You get a score in four areas and the first three steps to fix the weakest one.

Standard work

Is the work done the same way every time?

Critical operations have current, written instructions that operators actually use.

Two operators on different shifts would set up and run the same job the same way.

When a method changes, the documentation and training change with it.

Knowledge risk

Does the process depend on a few people?

If your most experienced setup person were away for two weeks, output and quality would hold.

New hires reach full speed on a critical operation in weeks, not months.

The reasons behind key settings and workarounds are written down, not just remembered.

Measurement and capability

Do you know how good the process really is?

You know the Cpk, or another capability measure, of your most critical features.

Scrap and rework are tracked by cause and by operation, not just as a total.

Inspection results are used to adjust the process, not only to accept or reject parts.

Constraint and flow

Do you know what limits output?

You can name the operation that limits output, and the data agrees with you.

Cycle times at that operation are measured, and you know how much they vary.

Decisions on overtime, outsourcing or new equipment are based on data about the constraint.