Launching new projects is the moment when companies typically focus on the technical side of the process: machines, parameters, tooling, or component quality. What often gets overlooked is the operator’s perspective. Introducing work standardization and TWI Job Instruction methodology at the very beginning – during the first trial builds – helps organizations avoid costly mistakes later on.
Why is work standardization critical when launching new projects?
Most companies are already familiar with the benefits of work standardization in existing, well-known processes. But the real value emerges when standardization is applied from the very start of launching new projects.
In early stages, process changes are quick and relatively inexpensive. Once a project reaches serial production, every modification comes with multiplied costs and delays.
Integrating standardization during PFMEA (Process Failure Mode and Effect Analysis) development allows the team to identify potential issues before they escalate. When technical solutions are not sufficient, human work becomes the safety net. Proper analysis of how the operator performs tasks uncovers risks that would otherwise surface only during serial production.
How does the process of standardization work in practice?
The process starts with experienced operators who also act as certified TWI Instructors. From the very first builds, they look at each operation not only as workers, but also as trainers preparing for future onboarding.
Key factors are carefully reviewed:
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task sequence,
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execution method,
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cycle time,
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workplace ergonomics.
The outcome is a clear work instruction that satisfies both process requirements and customer expectations. Because the standard is developed collaboratively, operators fully trust it – and resistance to change is minimized.
One of the biggest challenges in early phases is the lack of enough real parts for training. In our case, the solution was to create three reusable training kits:
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components were designed for multiple uses,
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chemical substances (glue, primer) were replaced with water,
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tools were identical to those in the final process.
This allowed operators to repeat tasks multiple times, fine-tune workstation layout, and capture realistic cycle times – all before SOP (Start of Production).
Visual support for operators
Strong visualization was another crucial element:
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step-by-step visual instructions at each station,
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an electronic operator panel with access to training videos,
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clear markings of critical steps in the process.
These tools enabled new employees to quickly learn safe and effective work methods.
The results – launching new projects
The project included 16 manual operations on one product and 14 on another – a setup where mistakes could easily happen. Yet the outcomes were remarkable:
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over 50,000 units produced,
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more than 750,000 components manually assembled,
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only 8 missed operations in total, all detected internally,
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most issues traced back to process-specific problems rather than operator error.
This demonstrates that standardization, when applied early, works almost like a technical safeguard for the process.
Why start with work standardization when launching new projects?
There is no universal template for developing work standards – each process requires a tailored approach. Still, practice proves that an early, well-prepared standard:
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reduces the risk of errors in mass production,
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accelerates new employee training,
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improves both safety and quality,
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builds a solid foundation for continuous improvement.
Conclusion – launching new projects
Launching new projects with work standardization and TWI methodology in mind is an investment that pays back many times over. Instead of fixing problems after SOP, companies that standardize early create stability, safety, and consistency right from the start.
If your organization is preparing for launching new projects, consider making work standardization one of the first steps. It’s the most effective way to ensure your operators work confidently and consistently – from the very first unit produced.
Bogusław Zambok has been with Cooper Standard in Bielsko-Biała for over 15 years, working as a Production Coordinator and TWI Trainer. Since 2015, he has specialized in the practical implementation of work standardization and the launch of new production projects.
As an expert in the Training Within Industry (TWI) program, he has been a speaker at multiple industry conferences, sharing his knowledge on work standardization and employee development. He has also conducted open workshops on TWI, engaging participants from various industrial sectors.
He combines extensive hands-on production experience with a strong passion for developing people and improving processes.
