Operational Diagnostic

5-Question Process Friction Audit

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

Maturity Rating Scale:
1 = Broken / Never (Complete Tribal Chaos)
3 = Mixed (Exists on paper, bypassed at 2:00 AM)
5 = Fully Embedded (Point-of-Use & Shift-Proof)
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?
1: Unmarked / Guesswork  →  5: Clear Painted Arcs / Limit Boards
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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?
1: Buried in PDF / Binder  →  5: Mounted at Machine Frame
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3. The "Magic 20%" Tribal Capture Does your documentation capture veteran operator adjustments and knacks, or only sanitized office steps?
1: In Veterans' Heads Only  →  5: Tactile Knacks Documented
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4. The Red-Line Protocol Can operators immediately red-line inaccurate instructions on the floor to trigger quick master document revisions?
1: 6-Month Committee Delay  →  5: Instant Floor Red-Line Channel
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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?
1: Scrap Spike / Call Bob  →  5: Flawless Repeatability
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