Reduction of SOP deviations

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rework

Reduction of SOP deviations

Design the system so the “right way” is the easy way

The Pain

Deviations usually signal system design gaps: unclear or hard-to-use instructions, layout/ergonomics that add friction, tool or material availability issues, and shift-related fatigue. Safety science’s “new view” is clear: what we call “human error” is typically a symptom of deeper system trouble, not the root cause.

Why it Matters?

When SOPs aren’t usable (too long, ambiguous, or mismatched to reality) and the work environment isn’t human-centered, deviations propagate, creating rework, hidden WIP, and schedule slips.

How Deltia solves it

Make deviations diagnosable as system signals. Deltia compares real work steps to SOP intent and highlights patterns by station, shift, product, or operator cohort, surfacing where the system puts people in a bind (e.g., unclear step, awkward reach, missing tool).
Close the loop with designable fixes. The reporting views (output/time, output per station, average cycle time, activity mix, % value-add time, staffing) reveal where instructions, layout, or material flow create friction, so you fix the system (SOP clarity, work design, kitting, tool placement), not the people.
Support adoption with human-centered content. Short, in-context digital SOPs and targeted micro-videos reduce cognitive load and standardize “the best known way,” aligning with standardized-work literature on cutting variability and defects.

On the shopfloor

A pump manufacturer battling high rework found that a fixture-application step was interpreted three different ways across shifts. Using Deltia, the team spotted the pattern within days, simplified the step in the SOP with a short on-screen clip, and stabilized the layout around the station. Rework fell by 30% and first-pass yield rose without blaming or retraining operators en masse.