The CHECK Process was created to give Supervisors and other shop floor personnel a simple tool to evaluate process conformance.
Before gathering data and conducting in-depth research to determine the root cause of process instability, it is important to verify that the operation is being performed according to specifications and standards.
We call this "Looking for Open-Windows".
The CHECK process serves as a guideline to make sure the basics are addressed consistently across all shifts.
Verify that all shifts are using correct work practices:
- Operators fully trained on all shifts? Was the training verified to be effective?
- Are there Visual Work Instructions available at the job station that outline the critical components of the operation?
- Do the Operators know the acceptance standards?
- Are the specified tools, sequences, and methods being employed?
Verify clean and orderly workstations:
- Is the workstation well-lighted?
- Confirm that there are no safety hazards or awkward ergonomics. If the operator has to struggle to perform the operation, it will not be done consistently.
Verify that all Equipment and Tooling is in proper working order and calibrated:
- Is there a documented Preventative Maintenance (PM) program, and are the PM checks being completed per the schedule?
- If the output of a machine is charted, what does the chart indicate?
Verify that a process is in place to ensure that defects are not passed to the next step in the process:
- Is there a means to identify defects?
- Is there a means to stop production or otherwise correct a defect before passing it on?
Keep Doing It!
Make the CHECK process part of the daily routine:
- Continually verify the operation every shift using the CHECK process. CONSISTENT ATTENTION IS THE KEY TO SUCCESS.
The CHECK process is a simple system for employees and supervisors. A specification is created or standardized across shifts, for each shift to calibrate to at the start of a new shift.
When analysis is done on processes following this calibration the variability created by different shifts behaviors is reduced. This practice enhances the ability of teams to get stronger data out of a system and more accurate representation of differences in processes if they exist.