Last month’s parts were perfect. This month — 14 rejections.
Same machine. Same drawing. Different operator.
That’s what happens when you don’t follow Standardized Work.
Toyota calls it:
“The most efficient combination of manpower, machines, and materials.”
We call it:
Doing it the same way, every single time.
What Is Standardized Work?
It’s not about making work robotic.
It’s about making good results repeatable.
Every part has a correct:
Cutting speed
Clamping direction
Deburring process
Cleaning sequence before inspection
When those steps are standardized, then:
Quality becomes predictable
Rework becomes rare
Even a new operator can match a senior’s result
Real Example #1 – VMC Shop Solved a $150 Tool Crash
A Pune job shop had an issue:
Every time a new operator ran a specific VMC job, the tool crashed into the fixture.
Why?
The Z-clearance value wasn’t clearly set — and no one explained the clamping depth.
Fix:
Printed a setup photo with tool offsets and clamp points
Laminated it on the machine
Supervisor checked it for the first 5 jobs
Result:
Zero crashes in 3 months
Tool savings: $150+ per month
Confidence: 10× more
Real Example #2 – Bore Size Issue Fixed in Rajkot CNC Shop
One supplier had a job with bore tolerance ±0.01 mm.
Parts kept getting rejected — not because of machine error, but operator habit.
Some operators cleaned the bore with air blow before final cut. Some didn’t.
That alone caused the tolerance issue.
Fix:
Final SOP step: “Air clean bore before finish pass”
Added a tick mark to daily checklist
Result:
Rejection rate dropped from 7.2% to 0.6% in one month
Why Buyers Should Care
Even if your supplier has:
🟢 Good machines
🟢 Good inspection
🟢 Good people
…none of that matters if each person runs the job differently.
Without Standardized Work:
❌ Sample parts ≠ actual delivery
❌ Setup depends on memory
❌ Rework happens silently
With Standardized Work:
✅ Predictable output
✅ Early detection of deviation
✅ Quality doesn’t depend on a single person
What TheSupplier Checks
We don’t just ask:
“Do you have an SOP?”
We check:
Is it printed and visible at the machine?
Is it explained in local language — not just English?
Does the operator mark steps with real proof (not just “tick-tick”)?
Can backup operators follow the same steps?
Because good parts don’t happen by chance.
They happen by design — and discipline.
📣 Want Your Orders Built on Process — Not Luck?
👉 See How We Evaluate Suppliers
📎 Upload Your RFQ
💬 Question for You
What’s one step in your supplier’s process that should be standardized — but isn’t?
👇 Share your story in the comments — and let’s fix it together.
📚 References
Toyota Global: https://global.toyota/en/company/vision-and-philosophy/production-system/
“The Toyota Way” – Jeffrey K. Liker
TheSupplier audit case reports (2023–2024)
