When is a Work Instruction not necessary or required?

Pancho

wikineer
Super Moderator
#11
Re: When isn't a Work Instruction necessary?

May I suggest that explicit can also mean electronically recorded sounds and images? For example, a simple video recording of a process or process steps can convey much more information and much clearer than a written document can.

A picture is worth a thousand words. :D
Indeed! Pics and video are great documentation aids. They also turn many a reluctant master into an eager performer/teacher.
 
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ScottK

Not out of the crisis
Staff member
Super Moderator
#12
Re: When isn't a Work Instruction necessary?

Our preference is to turn as much of the tacit knowledge in our organization as possible into explicit knowledge. In other words, we try to document all work that matters into written instructions.
That is certianly a noble goal.
In my case it's not practical because the variety is too high.

But there are ways around that!
I've approached it by having a detailed visual work instruction for a "family" of parts. A family being defined as parts that all have similar components in a similar configuration. Thus the method of assembly and test is always the same, just with different components parts by BOM.
The the BOMs are controlled - so we have part revision control.

The problem is when we have auditors who feel that each part number needs it own work instruction. Most can be reasoned with. But some.... :frust:
 

Stijloor

Staff member
Super Moderator
#13
Re: When isn't a Work Instruction necessary?

That is certianly a noble goal.
In my case it's not practical because the variety is too high.

But there are ways around that!
I've approached it by having a detailed visual work instruction for a "family" of parts. A family being defined as parts that all have similar components in a similar configuration. Thus the method of assembly and test is always the same, just with different components parts by BOM.
The the BOMs are controlled - so we have part revision control.

The problem is when we have auditors who feel that each part number needs it own work instruction. Most can be reasoned with. But some.... :frust:
If you can demonstrate that the assembly process is effective (process meets performance objectives), because the assemblers are competent, you have made your case. Period.

{Note: The automotive industry (ISO/TS 16949:2002(9), requires WI's.}

Folks argue too much with auditors because auditees have no recourse, no good evidence. Show results!

Stijloor.
 
M

mogluk

#14
Re: When isn't a Work Instruction necessary?

*emerges from lurk mode*

with ISO showing of results batch test results, insection reports are great ways to show control of your process. I agree that WI's should be used as a means to ensure meeting of specs...if a particular step keeps getting missed or a valuable inspection. Also if you have high turnover WI's are a means to ensure that a certain standard is maintained. but if you have a high turnover I would say thats the least of your worries...

I work in medical electronics so we have 100% test results for all units exiting. To avoid explicit assembly instructions we use a schematic and Bill's of Materials.
 
P

Polly Pure Bread

#15
Re: When isn't a Work Instruction necessary?

When I brought up the idea of having WIs for the machines here, I got some eyebrow raises. They explained that 1) their customers are not asking for it, and 2) it's impossible because the machinists are hired on 10+ years of experience, and training is performed as an apprenticeship. According to the foreman, "I can tell whether they know the machines or not after watching them for 90 days." (Small family company, so I don't know if it makes a difference.)

Do you have any recommendations for handling this, and is a WI necessary for everything?
Hi LexieB,

Do they agree with the documented procedures? Work instruction is, similar to a procedure, a detailed description of how to complete a specific task in an activity, but involving a single performer.
If the activity will be completed by performing tasks in sequence, then work instruction is necessary.
 
P

Polly Pure Bread

#16
Re: When isn't a Work Instruction necessary?

Even if your machinists/operators are one of the very best in that area, try to imagine what would happen if your good mechanists, God for bid, suddenly passed away. Will your business continue to operate without using a work instruction as reference and for how long? If no/less experienced-workers can comfortably do those then congratulations –you don’t need Work Instruction. What about in times of human resource/economic crises e.g. labor strikes, rise in absenteeism, work place accidents, etc.?
 
A

AMITRAAJSHARMA

#17
Re: When isn't a Work Instruction necessary?

OK - m reading a book called "How Toyota became the #1 Car Company in the world" by David Magee. I know it blemishes two pholisophies ISO and Lean but the objective is still the same - QUALITY.

Very well demonstrated in the book - STANDARDIZATION of the processes - typically attained by WIs - as mentioned in the ISO 9000 series.

Very young in my career I was made the MR of a cable company - the operators of the machines had like twice the experience than my age. Going upto them and convincing them about WIs on machines was like a child talking to his grandparents about the WISDOM life gives. But then (refer ISO 900X:1994) what has to be done has to be done. Thus followed a lotza :argue:, finally with Management support and positive competition (basically an R&R for the best and most innovative method to display WI et al) we managed to get that done.

And YES we did get the certification and a re-certification 3 yrs later...........:D

Cheers - Amit
 

SteelMaiden

Super Moderator
Super Moderator
#18
Re: When isn't a Work Instruction necessary?

Work instruction is, similar to a procedure, a detailed description of how to complete a specific task in an activity, but involving a single performer.
I think that work instructions might not fit that definition for everyone, but that is just my :2cents:. As stated, there is no "requirement" to have work instructions, but most of us find them useful, in whatever purpose we difine them. But, if they are not adding value to your process, you might as well not have them.
 

Bev D

Heretical Statistician
Staff member
Super Moderator
#19
Re: When isn't a Work Instruction necessary?

If you can demonstrate that the assembly process is effective (process meets performance objectives), because the assemblers are competent, you have made your case. Period.

{Note: The automotive industry (ISO/TS 16949:2002(9), requires WI's.}

Folks argue too much with auditors because auditees have no recourse, no good evidence. Show results!

Stijloor.
And the funny thing is that at Honda (and I suspect others) there are NO work instructions on how to assemble the car!! NONE. Nor do the associates ahve time to read them or look at them. Standardized work, visual work place and repetitive training keep everyone on task.
 

Bev D

Heretical Statistician
Staff member
Super Moderator
#20
Re: When isn't a Work Instruction necessary?

OK - m reading a book called "How Toyota became the #1 Car Company in the world" by David Magee. I know it blemishes two pholisophies ISO and Lean but the objective is still the same - QUALITY.

Very well demonstrated in the book - STANDARDIZATION of the processes - typically attained by WIs - as mentioned in the ISO 9000 series.

Cheers - Amit
actually Work instructions are antithetical to standardized work, rapid improvement and the Toyota Production System.

I think too many auditors look for work instructions because it's easy. It's difficult for them to ensure that a worker is performing an operation correctly without it written down in front of them...we too often do things in our organization to make it easier for the auditors even if its' not value add for us...that isn't the point of ISO.
 
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