What if you could ensure consistent quality without micromanaging every detail across your global operations? What if this method also improved overall quality management? An ASQ study indicates that process standardization reduces defects by 20% and can lower rework and scrap costs by 30%. And there are significant time benefits associated with these reductions.
At AlisQI, we’ve noticed that by standardizing tasks and automatizing their routine, our customers experienced similar benefits. One striking example is TenCate Grass. By digitizing one of their processes with AlisQI, the synthetic turf systems innovator cut time spent on manual tasks by a remarkable 86%. Standardization encouraged employees to follow set workflows, boosting efficiency, reducing miscommunication, and speeding up daily operational tasks.
Let's dive into the benefits of process standardization, and tips for implementing standardization in your business.
Reduce manual work and save time
One of the main benefits of standardizing your processes is time-saving. In a manufacturing environment, there are often many complex processes in place that require careful oversight. If the management of these processes isn’t standardized, inefficiencies can arise.
Going back to our TenCate Grass example, with one digitized process, daily operational tasks that previously took 15 minutes are now performed in just 2 minutes. This time saving will only scale up over weeks, months, years. And this only reflects the quality boost of one specific process. Manufacturers implementing this across their entire operation, could even save hundreds or thousands of hours each year!
Gain consistency, be compliant
Standard processes ensure uniform outputs across locations. They also help comply with regulations and standards. How? By documenting step-by-step procedures for each process.
The standard processes are then deployed across all sites to make sure everybody is on the same page. With process standardization in place, you get common standards across the board, with distributed teams that align perfectly despite physical distance. With everyone singing from the same hymn sheet, quality levels will increase, as variability that can cause defects is prevented.
In the case of TenCate Grass, consistency used to be a problem due to unspecific settings, the lack of naming conventions and unreliable manual work. After the change to digital, their smart QMS system recognized product orders and automatically couples them with the correct machine settings, readying them for immediate production. It even generates unique names that refer to all the attributes per product and product line, eliminating previous miscommunication and compliance issues.
Simplify training and onboarding
When you hire new people, trying to get them up to speed on all the processes and workflows can be a major headache. With standardized processes in place, onboarding becomes much easier as trainees simply follow well-documented workflows.
Structuring knowledge transfer in this way will help improve quality as it takes the guesswork out of mastering new processes and techniques, which is where mistakes are more likely to happen.
Another advantage is that onboarding time is shortened. Rather than spending days or weeks training new staff, then observing them closely, employees will gain confidence quickly thanks to the simplified handoff of standard instructions.
Unlock continuous improvement
A major part of a process standardization strategy is to regularly review it against benchmarks. This allows you to spot any gaps and identify new areas to apply best practices. Once you've identified these areas, you can update the standards and roll them out again. In this way, you are creating a process standardization cycle that embodies the spirit of continuous improvement.
Standardize Processes > Review Against Benchmarks > Identify Gaps > Update Standards > Repeat
Let's not forget the role of analytics. A QMS can automate the process of examining quality data, revealing opportunities for further improvements. This helps you to refine your standards based on real, data-driven insights.
By digitizing their process, TenCate Grass set the foundation for further improvements. They're looking forward to seeing the benefits of increased process control, enhanced traceability, and cultivating a culture of quality.
Proactive risk management
Standard protocols help us keep process variability in check, reducing the chances of errors and defects occurring.
Your QMS will work like a detective, tracking any deviations from the set standards. This allows you to swiftly spot potential risks and problem areas, then address issues before they become real headaches.
And there's more. Sticking to shared protocols also keeps legal risks at bay. Following set standards offers a layer of protection, helping to ensure that you meet regulatory compliance.
Improve supplier quality
Extending process standards across your supply chain can be extremely powerful. It allows you to align closely with your suppliers and make sure everyone is on the same page. In an age of growing supply chain disruptions, this can be very useful and result in cost savings.
As part of your process standardization, you can produce assessments that determine whether vendors meet quality standards or not. Underperformers can be dropped or retrained to meet your standards. This will help you to maintain the integrity of your supply chain.
With every supplier working to match your high standards, the quality of the components and parts you receive will also improve. It will have a domino effect on quality, whereby each supplier's enhancements contribute to raising the quality of your end product.
Increased customer satisfaction
Standard processes help deliver predictable and reliable outputs. Our products don't just meet specifications – they go above and beyond to meet customer quality expectations. Cutting down on quality issues such as defects and the need for rework will reduce complaints and lead to happier customers.
Showing a higher level of commitment doesn't just please our customers - it inspires their confidence in our brand. Confidence is key in any relationship, and it's no different between a brand and its customers. The more confident they are in our ability to deliver, the more likely they are to remain loyal to our brand.
Process standardization is a powerful tool to improve quality management. It enhances consistency, simplifies training, drives continuous improvement, and boosts customer satisfaction. But to truly leverage its benefits, you need a robust QMS like AlisQI.
Our system provides the tools and analytics to effectively standardize your processes, identify areas for improvement, and mitigate risks. Don't miss out on the opportunity to elevate your quality management. Try AlisQI today!