Standardization of Improvements – Making Gains the New Normal
1. The Problem It Solves
In many manufacturing organizations, improvements work—until they don’t. Performance improves immediately after a project, but slowly drifts back to previous levels. New operators follow old habits, procedures are ignored, and lessons learned fade.
This regression is rarely intentional. It happens because improvements remain dependent on individuals rather than being embedded in the system. Without standardization, even well-designed solutions are fragile.
Standardization exists to solve this problem. It ensures that improvements are consistently applied, understood, and sustained, turning temporary gains into permanent performance.
2. The Core Idea in Plain Language
Standardization means defining and embedding the best known way of working so that everyone performs the process consistently.
The core idea is simple:
If improvement is real, it must be repeatable.
Standardization is not about rigidity. It creates a stable baseline from which further improvement is possible. Without it, variation re-enters the process, and control becomes impossible.
3. How It Works in Real Life
After successful pilot testing, improvements are translated into clear standards. These may include updated work instructions, setup procedures, control limits, or training materials.
Standardization also includes aligning supporting systems such as planning parameters, maintenance routines, and quality checks.
In manufacturing environments, visual standards and clear documentation help ensure that improvements are applied correctly across shifts and teams.
Standardization is reinforced through training, coaching, and leadership example.
4. A Practical Example from a Manufacturing Environment
Consider a medium-sized manufacturer that reduces scrap through improved setup procedures. Initially, results are strong, but after a few months, scrap increases again.
The root cause is inconsistent application. Some operators follow the new procedure, others revert to old habits.
By standardizing the procedure, updating visual aids, and training all shifts, performance stabilizes. Scrap reduction becomes permanent.
Standardization turns improvement into routine.
5. What Makes It Succeed or Fail
Standardization fails when procedures are overly complex or disconnected from reality. If standards are impractical, they will be ignored.
Another failure mode is lack of reinforcement. Without leadership attention, standards erode.
Leadership behavior is critical. Leaders must model adherence to standards and treat deviations as opportunities to learn, not to blame.
Successful standardization creates stability and confidence.
How Standardization of Improvements Connects to Other Six Sigma Tools
Standardization builds on Pilot Testing results.
It supports Control Plans and Control Charts by defining expected behavior.
It enables Process Ownership by clarifying responsibilities.
It connects Improve and Control phases of DMAIC.
Closing Reflection
Standardization ensures that improvement efforts deliver lasting value. It transforms change from an event into a way of working.
In manufacturing environments where consistency drives quality and cost, this discipline is essential.
