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SOP Work Instruction (Job Card) Template Revisions question

cubix rube

Involved In Discussions
#1
We are a contract manufacturer that makes thousands of different parts for many different customers. We're certified to ISO 9001:2008, and ISO 13485:2003. We have a form in our system that we call a Job Card. This is what we use as work instructions for our operators on the floor. Each unique part we manufacture has its own Job Card, detailing the materials, equipment, process steps, etc.

When a new Job Card is created, it is created on whatever version of that controlled Job Card template is the current version at that time. If a part has not undergone any engineering changes, it's likely that that job card is still the original one that was developed so many years ago. This creates a situation where our current template is revision 3, however we still have thousands of other Job Cards already made up, but they are on template revision 2 or even 1, yet they are all active in our system at a time when the only current revision is technically Rev 3. First of all, is THIS a problem? If not, allow me to continue.

A change order has just come through for a part whose job card was originally produced on template rev. 1. When we revise this Job Card, can we simply revise the information that's on template rev.1, per the change order, or do we need to transfer all of that information over to template revision 3, which is the currently active version, and then update the content of that per the change order? The differences in the templates are such that it would require a lot of cutting and pasting to do it this way.

Unless there is a compelling reason to have to migrate older job cards to the newer template revision when Engineering Change Orders come through, I'd prefer to leave them in their original format, and only have to use the current form when generating a new Job Card. Would this be OK, if that's how I describe it in our QMS documentation, or is there something in the standard that would make this unacceptable?
 
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A

andrev

#2
To have more than one template for different parts(changes)pose a problem and may need some clear guidelines eg: every part/component have its own job card,which will result in more than 3 templates.

It will be less complicated to have only 1 template for all prod/comp. The change(difference) could be shown somewhere small on the job card.

Not sure if it is that simple though,but once the comments come in,your answer will too.
 
T

Tara Monson

#3
My first question is if the template had changes large enough that a revision was necessary, why would you not want this on all your job cards?

If the revisions are not required and you are okay with using the old templates with a revision of content, why was the template even revised?
 

insect warfare

QA=Question Authority
Trusted Information Resource
#4
My first question is if the template had changes large enough that a revision was necessary, why would you not want this on all your job cards?

If the revisions are not required and you are okay with using the old templates with a revision of content, why was the template even revised?
Exactly my thoughts. If it is not the right template, then it is not the right template for a specific reason (tracking, added functionality, more features, etc.). A gradual phase-out of the old versions should have been properly timed and executed when the new job cards were released for use. I would suggest reviewing the ECO process and seeing where improvements can be made in this area.

Brian :rolleyes:
 

Spanner

Starting to get Involved
#5
At the time the ECO is raised to change the format you should think about how you implement the change. So you could say only new jobs use the new template or as jobs on old templates are revised they should be transferred to the new template. Or all jobs will be upgraded to the new template in a certain time frame. The basis for the decision will depend on what has changed on the template.
 

cubix rube

Involved In Discussions
#6
Thank you, Spanner. That's what I was looking for. My main concern is whether the standard requires us to revise everything, or if I have the option to word the change in such a way as to omit some from the change, and change others. We have a job card for nearly each and every unique part we've ever run for any customer, since we started in this business over 20 years ago (We do purge those that we are aware of as no longer being ordered, but this still leaves thousands in the system). Some may never be ordered again, others are ordered only once every few years or so, and others are ordered several times per month. In order to avoid revising "dead" job cards, or spending time now, to revise a job that might not run for another 2 years, I'd like to word it such that new Job cards, and job cards being revised per an ECO will be migrated, but others would be left in their original format. If anybody sees a nonconformance in my future by taking this route, please share your opinion. Thanks!
 

leftoverture

Involved In Discussions
#7
Cubix rube you are taking the correct path. Meeting ISO standards is about having a system that makes sense for your business. What you outlined is perfectly sensible and you have a perfectly acceptable rationale for that decision. Document it that was and move forward accordingly.
 
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