In high-mix manufacturing, SOP drift quietly erodes throughput. Teams adapt around exceptions, but over time those workarounds become the process.
Three warning signs of SOP drift
- Different outcomes across shifts for the same job
- Changeovers that rely on “who is on duty” instead of the written method
- Recurring quality escapes after engineering updates
A simple operating model that works
- Lee (SOP owner): Owns revision governance and release cadence.
- Debbie (operations lead): Verifies execution consistency by shift and area.
- Manny (technician): Flags friction points where instructions break at point-of-work.
30-day pilot plan
- Select one critical workflow (setup, QC check, or changeover).
- Standardize one controlled instruction path and retire old variants.
- Track one KPI: first-pass yield, defect rate, or changeover time.
- Hold a weekly 15-minute review for revision and adoption gaps.
Expected outcome
Most SMB teams can reduce SOP-related rework by 10–15% in a month when instruction ownership and execution visibility are tightened together.