Hi Reader,

Have you ever seen a great process improvement fail simply because people went back to the old way of doing things?

One of the biggest challenges in Lean and Continuous Improvement is making sure that changes stick. That’s where Standard Work Instructions (SWIs) come in.

Why Standard Work Instructions Matter

Without clear documentation, improvements often fade over time as people revert to old habits or as new employees receive inconsistent training. SWIs ensure that:
✅ Everyone follows the best-known method consistently
✅ Training is faster and easier for new employees
✅ Improvements don’t disappear over time

How to Create Effective Standard Work Instructions

A good SWI is clear, visual, and easy to follow. Here’s a simple structure to use:

1. Title & Purpose – What the instruction is for and why it matters
2. Step-by-Step Process – Break down the task into simple steps
3. Key Points & Warnings – What to watch out for (e.g., safety risks, critical tolerances)
4. Visuals – Pictures, diagrams, or even video links to make instructions clearer
5. Approval & Revision History – Keep it up to date as improvements are made

Example in Action

A company struggling with inconsistent machine setup times used SWIs to document the best setup procedure. After implementing clear step-by-step instructions with visuals, setup time was reduced by 30%, and new operators learned the process much faster.

Get Your Free Standard Work Instruction Template

To help you create effective SWIs, I’ve put together a Standard Work Instruction Template you can download here:

This is one of the best tools for sustaining process improvements and ensuring that efficiency gains don’t disappear over time.

Have you used SWIs in your workplace? What’s been your biggest challenge in keeping improvements sustainable? Reply and let me know—I’d love to hear your thoughts!

Daniel Croft-Bednarski Learn Lean Sigma ​Learnleansigma.com​ ​​

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