Complete firstProcess Mapping
A documented process model with steps, roles and handoff points exists for the analysis scope.
Without: Without process model, analysis becomes inventory instead of standard-work assessment.
RunsheetOperations
Standard Work Analysis
ComplexityMedium
Time1-3 h
Participants2-6
FormatWorkshop
MaturityCanonical
01
Prerequisite
What needs to be finished first
02
Preparation
What needs to be ready before start
Materials
Observation sheet with columns step, target cycle time, actual cycle time, deviation, note; stopwatch; camera or video function (with consent); current standard if available; KPI extract from last 4 weeks.
People / roles
One analyst (lean or process engineer); two to four operators whose work is observed (informed and consenting); one supervisor with mandate to assess deviations without tipping into evaluation of the person.
Pre-read
Currently valid standard or explicit statement that none exists; shift model and variations; known special cases; KPI state against targets.
Time needed
1-2 days per process section
Setup
Communicate observation with all operators (purpose and privacy). Plan at least three full runs per operator. Choose observation points so ergonomic position and material flow are visible.
03
Core question
The one question this method answers
Which steps of the examined process are actually standardized, where are unwanted deviations, and which variation is useful?
04
Flow
Marker: Phase
| Step | Duration | Action | Hint |
|---|---|---|---|
1Phase 1: Review target standard | 30-60 min | Read currently valid standard, extract step list, write down target cycle times per step. If no standard exists, document explicitly and repurpose observation as baseline capture. | If the standard only exists as onboarding slide, it is not an operational standard. Separate written target from lived target. |
2Phase 2: Observation | 4-8 h | Observe at least three runs per operator. Note actual cycle time and deviations from standard per step. Document anomalies in sequence, tool choice, pauses, rework. | Operators will work more slowly when they feel observed. Behavior usually normalizes after 30 min. Discard first run per operator as warmup. |
3Phase 3: Variation analysis | 2-3 h | Categorize deviations: a) operator-related (routines, workarounds), b) material-related, c) equipment-related, d) standard-related (standard unclear or wrong). Create Pareto per category. | If standard-related deviations dominate, the standard is the problem, not execution. Ask operators which workarounds they already established. |
4Phase 4: Recommendations | 1-2 h | One concrete measure per top-3 deviation cause: sharpen standard, improve visualization, training, change equipment. Define owner and date. | Measure 'train operator better' is usually a symptom. If three operators independently develop same workaround, change standard, not person. |
05
Artifact
What comes out at the end
Form
Analysis report with target-actual comparison per process step, Pareto of deviation causes, categorized variation list, top-3 recommendations with owner and date, plus observation data per operator pseudonymized.
Versioning / ownership
Analysis date, shift sample and analyst in header. Use pseudonymized operator IDs (O1, O2, ...). Follow-up analyses as new version with comparison to previous version, old version archived not overwritten.
Tool alternatives
- Confluence page in operations space
- Excel or Google Sheet with pivot table per operator
- Markdown in repo under docs/operations/standard-work/
- Visual Management Board with photo documentation at workplace
standard-work-analysis-working-template.md
Compact working template for Standard Work Analysis with context, input, output artifacts, and next step.
Standard Work Analysis Working Matrix
| Element | Description | Rating | Evidence | Owner | Next step |
|---|---|---|---|---|---|
| 1 | |||||
| 2 | |||||
| 3 |
Output artifacts
- Standard Work Sheet:
- Deviation List:
- Improved Standard:
- Training Needs:
Decision or recommendation
What consequence follows from the matrix?
06
Example output
Concrete filled scenario, fictional example
standard-work-analysis-beispiel.md
Concrete filled scenario, fictional example
Standard Work Analysis — Assembly Line B, Shift 2 (2026-05-06)
Observed runs: 12 (4 operators, 3 cycles each)
Target cycle time total: 6 min 30 s according to standard v3.
Actual cycle time median: 7 min 12 s (range 6 min 05 s to 9 min 40 s).
Top-3 deviations:
- Step 4 (torque screw check): standard names no target torque. Operators use different wrenches. Measure: add target to standard, calibrated wrench at every station. Owner @marcus, by 2026-05-20.
- Step 7 (packaging): Operator O2 uses own pre-stacking workaround that saves 40 s. Measure: adopt workaround as new standard. Owner @anna, by 2026-05-13.
- Step 2 (material pickup): 60 m walking distance because picking cart position. Measure: move cart. Owner @ben Logistics, by 2026-05-13.
Other findings: Shift 2 has 18% more rework than shift 1 under same standard. Follow-up spike on cause planned.
07
Pitfalls
Recognize symptoms and steer against them
Trap
Observation feels like evaluation of person
Symptom
Operators work artificially slowly or reject observation.
What to do
Communicate purpose clearly: standard is assessed, not person. Observation sheet without names. Aggregate results anonymously. Value workaround findings.
Trap
Sample too small
Symptom
Only one operator or one shift observed, findings generalized.
What to do
At least three operators and both relevant shifts. Variation between shifts is often more important than average.
Trap
Standard assumed as given
Symptom
Deviations are interpreted as operator errors, standard is not questioned.
What to do
Invert question: what would a good operator do differently if following standard. If answer is 'nothing useful', standard needs repair.
Trap
Workarounds overlooked
Symptom
Operators mention tricks during break, report does not contain them.
What to do
Actively ask for 'small adjustments'. Workarounds are often better standards in waiting. Document at least three per observation day.
Trap
Recommendation 'more training'
Symptom
All measures become training, standard and equipment stay unchanged.
What to do
Training only if proven operator does not know standard. If they know it and still deviate, standard is the problem.
08
Stop criteria
Done signals checkable in under a minute
Operators refuse observation, consent is missing.
Privacy or labor agreement forbids cycle-time capture without co-determination.
Process runs under special conditions this week, observation not representative.
No documented standard exists and no willingness to standardize after baseline capture.
Process owner has already decided solution, analysis should only legitimize.
Material or equipment variation dominates, observing people yields no signal.
Finished the runsheet?
Go to the profile for purpose, similar methods, and sources or continue to the next method in the catalog.