Operational Diagnostic

5-Question Process Friction Audit

Assess whether your standard operating procedures survive the shop floor and the 2:00 AM shift change.

1. The Three-Second Rule Can an operator glance at a workstation or machine gauge and know within 3 seconds if the process is in spec?
2. Point-of-Use Delivery Are work instructions mounted directly at the machine frame (Level 3 Battle Cards) rather than in binders or digital folders?
3. The "Magic 20%" Tribal Capture Does your documentation capture veteran operator adjustments and knacks, or only sanitized office steps?
4. The Red-Line Protocol Can operators immediately red-line inaccurate instructions on the floor to trigger quick master document revisions?
5. Shift Change Survival If your senior lead operator calls out sick at 2:00 AM, will Shift B run the exact same process with zero scrap spikes?