What operations ACTUALLY REQUIRE work instructions?!
What operations ACTUALLY REQUIRE work instructions?!
(OP)
We have implemented a detailed product development process that requires work instructions for practically every operation/assembly. However, I need to know what manufacturing operations actually REQUIRE work instructions realistically. For example, in my opinion, most simple assembly processes would not require work instructions because it would be simply 1)Get part. 2)Attach part (paraphrasing...). So, I am finding that this stage in the process is more redundant than being helpful to the operators on the manufacturing floor. It also creates a lot of excess paper work that has to be tracked and maintained. I am looking to define what needs to have a work instruction so I can make it standard in the department. Thanks.





RE: What operations ACTUALLY REQUIRE work instructions?!
Customer Z wanted 80 of Widget X using configuration A and 20 of Widget Z using configuration B. etc...
Work instruction usually are pretty useful if you have a 1000 different configurations for 1000 products, they are kinda useful.
RE: What operations ACTUALLY REQUIRE work instructions?!
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RE: What operations ACTUALLY REQUIRE work instructions?!
I think we are thinking along the same lines here. So, basically if there are some quality check points or "critical" specifications involved, a work instruction would be useful. But, if it is just an assembly process (attaching parts with screws, etc), we should not use a work instruction. Correct?
RE: What operations ACTUALLY REQUIRE work instructions?!
If the assembly steps is complex or has many steps done at the same assembly step, then you may want instructions. They may not get used as aevery item is produced, but they will be there for new people or as a reminder.
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RE: What operations ACTUALLY REQUIRE work instructions?!
If you have a general assembly procedure that states “always use loc-tite on threads” and a particular fastener shouldn’t have loc-tite, then that might need a work instruction, and vice versa. I mostly agree with looslib, in that published work instructions may not always be read or followed, but by generating them they will exist and can be referenced for future occurrences (training).
I think we are on the same page AuburnIE.
"Art without engineering is dreaming; Engineering without art is calculating."
Steven K. Roberts, Technomad
Have you read FAQ731-376 to make the best use of Eng-Tips Forums?
RE: What operations ACTUALLY REQUIRE work instructions?!
RE: What operations ACTUALLY REQUIRE work instructions?!
RE: What operations ACTUALLY REQUIRE work instructions?!
Quality is another reason for work instructions to convey the varying requirements. We call out not only to use Loctite but to use a specific Loctite or thread sealant or silicone sealant. Different torque tools are used including break over type tools, air stall tools and DC tools.
The instructions are not read on a daily basis except for when substitute people are brought on line for whatever reason and as training tools for new associates.
RE: What operations ACTUALLY REQUIRE work instructions?!
Work Instructions are not a catch all and are only successful in concert with proper supervision and training. In addition, we always have a statement that associated assembly drawings and their ECOs take precedence over the work instructions should there be a discrepancy.
I agree with and utilize what automatic2 suggests in having the assemblers draft the procedures. It helps them take ownership and tends to reduce the amount of technical jargon.
Regards
RE: What operations ACTUALLY REQUIRE work instructions?!
RE: What operations ACTUALLY REQUIRE work instructions?!
RE: What operations ACTUALLY REQUIRE work instructions?!
Regards,
RE: What operations ACTUALLY REQUIRE work instructions?!
RE: What operations ACTUALLY REQUIRE work instructions?!
RE: What operations ACTUALLY REQUIRE work instructions?!
Regards,
RE: What operations ACTUALLY REQUIRE work instructions?!
At Dell the simplest of tasks is time studied and performed in a standard fashion, the minutest movement is studied and if analysed as wasted movement - this is erased from SOP.
The advantage of SOP is discipline, greatly helps in cellular manufacturing/assembly. The concept of takt is useful in this aspect too because this sets the pace. IT may not be necessary that completing a task fast is good.
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Mech Rulz
RE: What operations ACTUALLY REQUIRE work instructions?!
I used it in engineering design, specifically gear/gearbox design. In the company in question, there was a dearth of knowledge in that specialty. I did my part to remove the fog in power calculations, gear support and bearings, lubrication, and gear progressions in pitch, face width and gear diameter as you progress from low torque to high torque.
RE: What operations ACTUALLY REQUIRE work instructions?!
On some simple jobs which simply need memory joggers, key points highlighting etc. We now use a photographic storyboard system. Rather than ' step 1, fit bolt a to part b' we show a pic of it being done with a one liner reminder of any key points. A picture speaks a thousand words and even with the most experienced operators its useful after they've been on holiday, or just when they're having an off day. We put these either at the work stations on the wall, or have them available in a local folder ready laminated and to hand.
Other more detailed work instructions we hold in training manuals, used for training but once the operator is trained up they are retained for reference only.
Finally, we have special work instructions for things which are not done so often or which require major controls e.g. procedures involving gas or electrical isolation. These use pictures and a fair amount of detailed writing as well to ensure that in these cases there is no opportunity for miscommunication or confusion.
In essence its horses for courses. Find something that works for you. I would however stress that procedures are very useful things, and if you have them don't lose them, the day will come when someone wants to examine them (e.g. legislative bodies) new operators join the team, or improvements want to be made. In these cases they are invaluable.
If paper trails are a hassle then the use of a 'manual' will work a treat, one single document control for a whole host of procedures, keeps the ISO auditors happy and makes life a bit easier.
Good luck !
RE: What operations ACTUALLY REQUIRE work instructions?!
RE: What operations ACTUALLY REQUIRE work instructions?!
*remove risk of losing knowledge should someone leave the company
*Capture the corect method for training
*have a standard time for the operation
*have a known level of quality output
You should always invole the operators, who knows how to do thir job better? I use it for this reason not to save me from doing it. Also would you like your boss writing you an SOP and telling you work to this without you having an input?
In short every operation should have an SOP.
RE: What operations ACTUALLY REQUIRE work instructions?!
I know my common practice is to have a well seasoned assembler perform what i call a "control build" where we sit and document step by step instructions using minimal text and digital pictures.
I use this technique for existing products, for new product releases, I perform a prototype build where I determine the build sequence, than thru continious improvement will revise the sequence as the operators become the experts.
So my opnion is, anything that adds value, needs to be documented.
RE: What operations ACTUALLY REQUIRE work instructions?!
This process may be redundant, but if you rotate your people; you will see the need for them.
NOTE:
When your customers visit your site; they can see the effort the company places on Standard Data the same for each and every part produced regardless of who is working in the cell.
Everyone works the data the same.
Ed Spearman