Geoff Crossley, Senior Manufacturing Advisor, reflects on a fundamental lesson from the Lean Champion programme: the importance of setting and upholding standards. 

Why standards are the foundation of manufacturing success

Manufacturing thrives on standards like Standard Operating Procedures (SOPs), which create consistency, repeatability, and uniformity. These are crucial foundation for ensuring productivity, maintaining quality, and satisfying customers. 

However, when standards are neglected, the entire system unravels. Leadership plays a key role here. If a manufacturing leader passively accepts deviations – even small ones – it sets a precedent that standards are optional. For example, ignoring an untidy workstation can foster an "it’s not my job" culture that stifles continuous improvement.

Walking by: A warning sign

Here’s a practical example: At a steel fabrication plant, used tools and rubbish were strewn across the floor, while tools like PARP helmets and mag drill stands were left scattered. This created safety hazards, wasted time searching for tools, and disrupted workflows.

What went wrong? Leaders were hesitant to confront these issues, inadvertently signalling that such behaviours were acceptable. Sustaining improvements is one of the most challenging aspects of lean implementation, but without intervention, chaos persisted. A lack of leadership perpetuated inefficiencies, unpredictability, and safety concerns on the shop floor.

Key takeaway: "Whatever you walk by is the new standard"

As a manufacturing leader, every action sends a message. Ignoring an issue signal that it’s acceptable. Instead, while addressing deviations promptly sets a standard for everyone to follow.  Before walking by the next untidy workstation or overlooked procedure, think twice. Upholding standards is the first step toward building a disciplined, efficient, and successful manufacturing operation.

Lean principles in action

While acknowledging sustaining standards & improvements can be a challenge there is good news too. Kata, is a lean principle derived from martial arts where the student repeats a movement until it becomes second nature or unconscious competence. This principle has been adopted by manufacturing. When standards are consistently maintained, discussed, and embedded into daily operation, they become second nature. 

Most people working on the shop floor in a factory would challenge a colleague operating dangerously. Not complying with PPE standards (shoes, glasses, ear-defenders) would also be challenged. Kata is normalising the expectation that everyone can, will and should challenge non-compliance to a standard operating procedure, even beyond health and safety concerns.

Back to the example of the fabrication plant, adopting Kata transformed production. Leaders actively addressed deviations, ensuring everyone understood and followed procedures. This in turn created a culture of accountability and order, where SOPs became the foundation for safe, repeatable, and efficient workflows.

Real-Life Success Stories

Bolton-based ductwork manufacturer, Pure Fabs, illustrates how upholding standards drives change. Director Pete Connor set an example by enforcing PPE standards across the shop floor. His consistent leadership reinforced a culture of compliance and safety, showcasing how maintaining standards drives positive change.

How we can help

At GM Business Growth Hub, our expert Manufacturing Advisors specialise in helping businesses like yours set and sustain standards using lean principles. Whether you’re new to these concepts or seeking a fresh perspective, our fully funded one-to-one consultation service can identify areas for improvement and help you achieve greater productivity and profitability. Contact us today to begin the conversation!