johnnybegood said:
Can anyone share how do you deal with operators who fail to follow work instruction?
If you have a business system in place, you'll be able to measure the work process in question. The personnel who "fail to follow" work instructions, often fail to follow for valid reasons. The valid reasons may be: a work process that is unsafe, doesn't ensure quality, has hidden factory associated with it, over cycles and often there are social conditions associated with personnel performance. You also have to ask the question: was this operator involved in the set up of this work instruction, the work area and all the associated functions that should ensure process performance levels?
Assess, measure and be prepared to reform the process to conform to the operators environmental requirements, such as ergonomics and safety.
Re-training may be a step that can verify personal knowledge of work processes and what's expected. The extreme of this scenario is that, the process in question may be "Delta". In this case, personnel who perform Delta processes are constrained by legislation to perform an acceptable level of conformance to expectations. Again training is the key stone.
This scenario can indeed be very easy or extremely difficult to deal with. you must however measure the process in question, data that contains the work process performance measures are important.
Wallace.