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Over Complicated Work Instructions

W

wezzer1982

#21
Hi All,

Thanks for the replies. Sorry I cannot work out how to attach more than one quotes but there are some good points and lots of help here. I didn't expect this much of a reply but I knew it was a debatable subject. Sorry I didn't reply sooner.

As I thought, I have answered the question already myself but I wanted to put it up here for confirmation and to get some other opinions going as it is not a clear yes / no answer.

You have all given me more awareness that its whatever the requirements of my business are that matters (which is cool, thanks). I knew there wasn't a requirement in the standard as to how much detail is required I just wanted to open the debate as to where we draw the line.

The example of the solder is what bought it to my attention, this is a real example. The example about the Turn on Computer was an exaggerated example. But there lies the debate I feel. Can we ever assume things in Quality? I would assume that a skilled electrical worker can carryout basic soldering work. I would also assume that someone applying for a position in an office would know the basics of how to use a computer. I agree that there will be a probationary period where you would perhaps find out if someone is not up to scratch but why let it get that far? Are we saying that we have to test everybody for their basic skills to ensure competence?

The reason why I feel we cannot assume is because in my company we do deal with a lot of temps and as you may have noticed I am based in China (originally UK) where we have a lot of skilled worker turn-around and not a lot of competence (this is not a generic China statement, just my experience). We therefore spend too much time on training and ensuring competence than normal. Another reason is that if we are sending this work out to a sub-contractor we should be able to assume that the supplier (if approved) have the ability to produce standard soldering. Or do we need to see evidence of each workers competence at a sub-contractor? How would we go about that?

Another thing is that if we send the work to a sub-contractor and he solders incorrectly or poorly how do I reject it back to them? Where is my evidence of our solder requirements?

These are some questions that probably do not apply to most businesses as you would have a robust hiring process. Its not there for me yet :(

The things I have learnt from this though is that –

Work Instructions and Job Descriptions go hand in hand – thanks adickerson – I never thought of it this way when writing a process or work instruction

Usually it is a 'trade off' between what abilities/competence people have and how much we need to write down. – colpart – this is the answer for me I feel. It is a trade off and in my situation the best solution (although over the top) should be to detail all requirements, even requirement that should be covered in the persons job description. This way we will have the documentation to train, follow, check and the evidence to reject against if not conforming.

When questioned about the ridiculousness of doing so, we were told the instruction needed to be able to be understood by the proverbial "man off the street" and that was the corporate standard. – rand T – I also had this in mind when producing documents – can someone directly take over this job if the current operator quits today. With the above case in mind though, we are assuming the replacement will also be a skilled electrical worker. So creating instructions for the “Man on the Street” is a bit too over the top.

Thanks again for all your replies, I have been looking around here for a while but never really got involved. Glad I did on this occasion.:agree:

Cheers :thanx:

Wes
 
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J

JaneB

#22
Wezzer,
Glad you asked the question - a good discussion is a great thing to have, as is learning from it.
Can you ever assume things? Well, you can certainly (and should) specify your requirements - that's what the Standard means by specifying the competencies you need.
I would assume that a skilled electrical worker can carryout basic soldering work. I would also assume that someone applying for a position in an office would know the basics of how to use a computer. I agree that there will be a probationary period where you would perhaps find out if someone is not up to scratch but why let it get that far? Are we saying that we have to test everybody for their basic skills to ensure competence?
You 'shouldn't have to' but it may depend on your recruiting process perhaps. If you're getting a lot of basic failures in skills, then perhaps you do need to.

Another thing is that if we send the work to a sub-contractor and he solders incorrectly or poorly how do I reject it back to them? Where is my evidence of our solder requirements?
Specify your requirements to the subcontractor. Again, that's what's meant in the Purchasing clause. How do you reject it? Simple - don't take delivery, refuse to accept it and demand it meet the specified requirements. Raise an NC if you wish to, or just refuse to accept - whichver. Naturally, loop that back into supplier management and monitoring.

Overall, try not to forget that it's a quality management system. And in a system all the parts work together and interact, so that the whole is more than just the sum of the individual parts. So yes, instructions/procedures and job descriptions go together... as does recruiting/training/competency. And so on and so on

And yes, ultimately there's always a tradeoff - how much do I write?.

Also yes, writing instructions for 'everyman/woman off the street' is just plain ridiculous. (There was a fad for that, but I believed it died out - thankfully - quite some years ago when it dawned on people just how nonsensical it was.) Always determine before you write who you're mainly writing for and what the purpose is... and then write for them.

Anyone writing "for everyone" is doomed to be read by no-one. There's always a primary audience - the trick is to focus on that.
 
J
#23
Jane, as always, is spot on with her responses....

Something else that occurred to me is that - years ago when I was dealing with a company who did nuclear work (and we, as their supplier, were not "Nuke") they had a document listing all the purchase requirements that might be necessary for any component that they might purchase outside.
The man in charge of such purchases would then check off the ones that applied to a specific order being sent to us. So the cocument contained a header with their purchase order number, date, a list of checked items and his signature.

It occurred to me that with today's computer software, rather than a checklist, something like this could be constructed with necessary requirements/specifications/work instructions at the level needed while avoiding excess verbage where not needed.

Peace
James
 
A

adickerson

#24
Yeah, people try to sell that all the time...and yet, they still hold some importance to training. Interesting paradox, is it not? It might work as long as you have no visual or other sensory inspection as detection. "They" do like to blame "the system". It is a nebulous enough of a target to never be wrong. Interesting to exclude training from the "system", huh?
I don't think training should be removed from the overall QMS. However I would make training a separate program from the production line. At least in this specific case of electronic wires. If there is a high amount of turn over like the original poster claims then having a strong and robust training program is valuable.

I see what you are saying and in some companies it may work to fully immigrate training and production - an apprentice training to be a master machinist comes to mind. So, in some places that may work better.

Trust and verify. But verify to what? Usually the work instructions. I typically feel if a worker makes a mistake, and there was no work instruction to identify to problem, it is your fault, not theirs.
Detection methods and performance standards should be in the work instructions. Like I said, work Instructions should be specific to a process and should provide the details specific to the process. I would always consider the measures of a process to be relevant details specific to the process.

I like to use a tool called the "Turtle Diagram." This lets me really map out the details of the process and what needs to be covered in a work instruction.

If there is a work instruction, and you have evidence they were trained, then you have something to hang your hat on.
No you don't. If bad product gets out the door it is the problem of the quality department. There is no excuse. Even if a employee tries to deliberately sabotage things or if management tries to ship non-conforming product out the door, at the end of the day it is still the problem of the quality department. The lack of detection of problems before things shipped or not making a strong case for quality to upper management comes back to us, it is our fault when problems happen.
 

bobdoering

Stop X-bar/R Madness!!
Trusted Information Resource
#25
Here is an interesting point - did anyone ever ask the operators if they felt the instructions were over complicated complete or not? They are the customers of the document, and I have not read one comment (unless I missed it) that even addresses their satisfaction.

Interesting, huh?
 
A

adickerson

#26
Here is an interesting point - did anyone ever ask the operators if they felt the instructions were over complicated complete or not? They are the customers of the document, and I have not read one comment (unless I missed it) that even addresses their satisfaction.

Interesting, huh?
That is maybe the best advice to come out of this discussion. If we assume the worker is the most variable part of the process (fair assumption I think) and the person using the document, I don't see how they can be left out of the design of the work instructions. I think getting feedback from the workers is a great idea and a good starting point.
 
J
#28
(Snip)
No you don't. If bad product gets out the door it is the problem of the quality department. There is no excuse. Even if a employee tries to deliberately sabotage things or if management tries to ship non-conforming product out the door, at the end of the day it is still the problem of the quality department. The lack of detection of problems before things shipped or not making a strong case for quality to upper management comes back to us, it is our fault when problems happen.
I agree with Jane - - - Huh???

If an employee deliberately sabotages something that is quality's fault? If management overrides and ships non-conforming product that is quality's fault? No excuses???

If either of these things happen (or others) there are problems in the company that go WWAAYY beyond Quality issues.

Even if the system calls for 100% inspection, I'm sure that the old adage still holds true that 100% inspection is not 100% perfect.....

Caution Rant ahead: :mad:
I will even go further and, just to counterbalance your comment, if bad product gets out the door it is Never the fault of quality.....Well almost never. :notme:
The reason I say this is because bad parts should not be made, and if made should not be passed on. Work instructions etc, including critical inspection features etc. should all be determined designed and executed by those responsible for producing the parts....
One of the things that Quality departments have been working on over the last 30 plus years is to move away from "inspection"....
Quality is the responsibility of the people making the parts.....No one else.

Now that I got my rant out of the way......

If bad product gets out there are many who must share responsibility...It is almost never the responsibility of the quality department alone....
Quality is everyones job...That was and is a good "catch phrase"
So its the Responsibility ("fault") when bad product is shipped....

Peace
James
 
W

wezzer1982

#29
Thanks again Jane,

I learn from this site everyday :) there are usually many different opinions and every company is different, but at the end of the day we all have a main goal – to satisfy the customer and continually improve how we go about that. Its what makes this job interesting :confused:

I agree that the document should be designed around the worker (customer) and they would usually draft it up themselves. We would then work on it together and release. I now realise that its too much to put standard processes into a Work Instruction that would be used by a qualified worker trained to do this standard process. I would only put information that is different in my company to standard process. In the current situation I am in and what would be best for the business I would detail standard processes as our staff turn-around and supplier approval is not robust enough.

Regarding “Poor Quality is Quality Departments fault” I cannot agree. I agree with JRKH. And I fully believe its everyone’s responsibility to ensure they produce to the best possible standard. Stores ensure that they provide the correct parts to their customer the Assembly Shop > Assembly Shop ensure they provide conforming product to their customer the Electrical Department etc. If the drawings and Work Instructions are available to follow we should be able to believe that they have been followed and the worker has completed to the required level without requirement for 100% inspection.

If there are issues with this then Quality Inspection is required final sign off. If issues are found there then Corrective and Preventive Actions take place.

Cheers

Wes
 
J

JaneB

#30
Yes, we all learn something, which is one of the reasons why the Cove is fun.
I don't actually consider the person using a procedure/instruction/what have you as a 'customer' - after all, they often don't want the things,and don't always ask for them and certainly don't pay for them! But I do consider them as a highly important stakeholder and would always (wherever and whenever possible) get their input and feedback on them. It's no use me writing what I consider a fine and dandy, crystal clear procedure if they can't follow it and don't like it!

Ultimately it always comes down to an individual call on what's right for you, in your context and in your situation. But it's often useful to be able to bounce things off an interested and informed audience, such as here in the Cove!
 
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