CHECK Process to Ensure Smooth running Process

CHECK Process is one of the tools used on Lean Six Sigma-based projects to facilitate the supervisors and project teams in evaluating process performance.

Before collecting data and conducting in-depth research to locate root causes that lead to inefficient processes, we must ensure operations are running according to predetermined specifications and standards. Practitioners call it " looking for open-windows ". The analogy looks like this:

If the room temperature gets cold, before we do a complicated analysis of the function and insulation capabilities of the wall, should we find out if there is an open window? If there is, close it. Then make sure whether the fireplace is dead or not.

The CHECK process serves as a guide in making sure the basics have been done consistently across shifts. CHECK itself is an abbreviation of Correct-Housekeeping-Equipment-Contain-Keep doing it. Here is the description for each segment:

Correct

Make sure the entire shift has implemented the correct work practices:

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    • Have all operators been trained?
    
    
    • Is the training effective?
    
    
    • Are visual work instructions available throughout the work area? Does the visual instruction have explained all the critical components of the operation?
    
    
    • Does the operator know the existing standards?
    
    
    • Are specific tools, work sequences, and methods implemented?

Housekeeping

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    Make sure the work area is clean and orderly, and always tidy:
    
    • Is the lighting in the work area adequate?
    
    
    • Make sure there is nothing that threatens safety or ergonomic mismatch. If the operator has difficulty / inconvenience in doing the job, then the consistency of the work can not be guaranteed.

Equipment

Make sure all equipment and machines are in top condition and calibrated:

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    • Is there a document Preventive Maintenance (PM) program, and is the PM test completed?
    
    
    • If the output of the machine has been map, what indicates the mapping?

Contain

• Make sure the process is set up so that the defects or errors do not roll over to the next process:
  
  
  
  • Is there a means or attempt to identify defects?
  
  
  • Is there a means or effort to stop production or repair defects before the process rolls to the next stage?

Keep Doing It!

Make the CHECK process a daily routine at the factory. Verifying the operation on each shift on an ongoing basis ensures the process runs smoothly. Consistent attention is the key to success.

Conclusion

CHECK Process is a simple system, which every staff and supervisor can do. Specifications and standardization should be available to guide the work on each shift, and each shift is calibrate before the shift process begins. This is complete to prevent and reduce variations due to different shifts. This CHECK tool will enhance the team's ability to collect data on stronger systems, and become an accurate representation of processes.