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"Selling" the idea of using Work Orders

M

MEDQA

#1
Hello to All,

I'm trying to sell the idea of using work orders. We use them in some areas, but not all. I'm getting some resistance because the responsible person is overwhelmed at the thought of issuing them. I'm seeking some input on how to "sell" the idea.

Note, we are expected to be iso-9001 compliant.


thank you,
 
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Jen Kirley

Quality and Auditing Expert
Staff member
Admin
#3
Re: "Selling" the idea of using work orders..

What is used in other areas - how is the production controlled?

Would those other areas be part of the audit scope under the standard you want to register to?

What are the advantages besides registration to a standard? Any? That is, can you point to scrap resulting from not using the work order?

Can a previous work order be used as a basis for making repeating orders?

If being overwhelmed is the issue by itself, I wonder how many of these things must be produced, how long it takes (how complex is the template and the process to fill it out) and if this is work piled on top of other duties. The standard does ask for management to provide adequate resources, and that includes manpower to achieve and maintain controlled processes.

Outside of that fact we have just the pros and cons. What benefit do they bring, and what burden they represent to this person (is only one person able to do those? If so, what happens if (s)he wins the Powerball and disappears?).
 
M

MEDQA

#4
Each area functions differently but all are expected to be ISO 9001 compliant.
At some point this year, we will implement MRP software that will aid in planning by allocating materials via a work order. The work order will become the lot # for which inventory can be tracked etc.

An actual Planner is also on the list of resources to obtain.


Area 1
w/o is issued to communicate how many pcs are needed and when they are needed.

  • this seems to work well in this area.

Area 2
w/o is issued to communicate production lot # assignment. The majority of the time, there is no end date or end qty given. Just run until you no longer have material from supplier A, then change to a new lot # / work order # to use supplier B. These w/o / lot #'s are sequential and not repeated.

  • Special instructions are often missed or not included (i.e. run x amount of parts from supplier A material, under concession or using trial material)
  • operators guess what w/o / lot # they are changing over to and guess wrong. Then, we need to make lot # corrections on documentation and data entry.
  • operators assume they are to continue to run the same part number when the machine should be changed over.
  • I would like to post the w/o at each machine so it is clear what is being produced. I would like a bar coded lot number on the w/o that can be scanned into data collection vs manual entry.
Area 3
Completes 1 or 2 secondary processes on Area 2 production. The need for these processes is dependent on whether the parts are used at a sister company or used in house.



Area 2 is located in another building approx 30 minutes away. A packing list from Area 2 is used to communicate whether the parts will be used in house or shipped out.


  • I find this document to be very limited and unable to communicate special circumstances. (use FIFO or we need x amount of each part by 00/00/00, changes to ship vs keep, changes to add / remove secondary process)
Area 4
is using the same run run run method as Area 2, with the exception that no w/o - lot # has been issued yet. This area has just re-started after 2 yrs so I'm not aware of all the process shortcomings.
 

somashekar

Staff member
Super Moderator
#5
Hello to All,

I'm trying to sell the idea of using work orders. We use them in some areas, but not all. I'm getting some resistance because the responsible person is overwhelmed at the thought of issuing them. I'm seeking some input on how to "sell" the idea.

Note, we are expected to be iso-9001 compliant.


thank you,
I am keeping the ISO9001 aside for now.
I am focusing on the work order.
Material is money in an other form. This money is put by the owner, bank, public, interested parties, partners, ~~ - ~~
If it is in the custody of the factory, then the factory is accountable. The factory someone who has the authority to move the material from stage x to stage next and so on has to account for the good use of the material or the reason for its non-use, like a processing rejection, supplier process rejection, wrong part, and such.
Is extra material used without authorization ?
Are good / bad materials further getting into the draw and shelf of production personnel ?
Are there any theft, pilferage ?
Are they getting exactly processed to a customer requirement, such that the materials (Money) is getting converted into Product (Money) and therefore meeting customer requirement (Purpose of Money in Business)
The one who holds the materials and processes it stands accountable, and the evidence of his accountability is in the records of the work order processing.
Now lets come back to ISO9001.
The 7.5.1 calls for control of production and service provision.
The organization shall plan and carry out production and service provision under controlled conditions.
Controlled conditions shall include, as applicable,


f) the implementation of product release, delivery and post-delivery activities

Map your business intent to ISO9001 statements seriously.

How do you wish to implement material releases within so as to implement product release, and product delivery ?

There can be many ways, but for me the simplest and most logical way is to implement material releases from stage to stage until the product release (simply a Work order process) so that I am happy, the Financiers are happy, my System is happy, my Customers are happy, and along the way ISO9001 (auditor) is also happy.
 
M

MEDQA

#6
Thank you somashekar. You have provided some simple language which may help me to communicate why this is important and specifically what we are missing in certain areas.

This conversation has also helped bring light to light some other "roots" to address.
 
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