When is a Work Instruction not necessary or required?

Helmut Jilling

Auditor / Consultant
#21
Re: When isn't a Work Instruction necessary?

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.
Lovely approach - bake it into the process...I think some work instructions add little value.
 
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Helmut Jilling

Auditor / Consultant
#22
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
While I am not a big promoter of work instructions, the purpose is not for the current employees. The value is it captures the best practices learned for the future.
 
P

Polly Pure Bread

#23
Re: When isn't a Work Instruction necessary?

I think it’s a requirement if you need it. Read:
The quality management system documentation shall include
4.2.1d Documents needed by the organization to ensure the effective planning, operation and control of processes.
What are the examples of these documents? Procedures (aside from the 6 mandatory), operating manual, job description, work instructions, guidelines, forms (e.g. document change request, management review input, nonconformity report, preventive action plan, etc).

Now LexieB, the question is:

Do you need it? The answer is yes if it has decisive influence on the final output.:D
 

ScottK

Not out of the crisis
Staff member
Super Moderator
#24
Re: When isn't a Work Instruction necessary?

I think it’s a requirement if you need it. Read:

What are the examples of these documents? Procedures (aside from the 6 mandatory), operating manual, job description, work instructions, guidelines, forms (e.g. document change request, management review input, nonconformity report, preventive action plan, etc).

Now LexieB, the question is:

Do you need it? The answer is yes if it has decisive influence on the final output.:D

it can't be a requirement on an "if you need it basis".

It's either a requirement or it's not. The requirement is "documents", not work instructions. In many cases a bill of materials and/or a controlled drawing is enough.
 
S

Sorin

#25
Re: When isn't a Work Instruction necessary?

As always (and I am quite sick about this) it boils down to "is it or not a standard requirement".

Forget the damn standard for one second and think in terms of profitability and efficiency for the company.

It's that simple. You have 2 cases: high or low personnel turnover.

1.Low personnel turnover.
The answer is training, training, training. And even in this case you need BOMs and parts folder/files and drawings and so on and so forth, (and that amounts to a WI cause it contains data necessary to do the work in question) for reference because nobody lives forever and/or is able to remember EVERYTHING.

2.High personnel turnover
Work Instructions / Pictorials ... Call'em as you like, you'll need them or you'll be stuck with a high rate of scrap.
 

ScottK

Not out of the crisis
Staff member
Super Moderator
#26
Re: When isn't a Work Instruction necessary?

As always (and I am quite sick about this) it boils down to "is it or not a standard requirement".

Forget the damn standard for one second and think in terms of profitability and efficiency for the company.

It's that simple. You have 2 cases: high or low personnel turnover.

1.Low personnel turnover.
The answer is training, training, training. And even in this case you need BOMs and parts folder/files and drawings and so on and so forth, (and that amounts to a WI cause it contains data necessary to do the work in question) for reference because nobody lives forever and/or is able to remember EVERYTHING.

2.High personnel turnover
Work Instructions / Pictorials ... Call'em as you like, you'll need them or you'll be stuck with a high rate of scrap.
I see what you're saying and don't disagree, but the whole point of the post is that the OP is going to go for registration.

So this particular topic has everything to do with the standard.
 
B

B.Read - 2010

#27
Re: When isn't a Work Instruction necessary?

Lexie,

I have somewhat the same issue as I am the Quality Manager (whole dept) in a small company and get the same response regarding WIs. I would say that WIs:
1) ensure consistency among different operators
2) are objective evidence to meeting the requirements of 9001-2008, 7.5.1 Control of Production and Service Provision.
3) provide for control of the process. A controlled process is easier to monitor when trying to watch for spikes and indications of nonconformities
4) Lastly, without WIs; what are you using to audit to when doing process audits?

Bryan
 

Randy

Super Moderator
#28
Re: When isn't a Work Instruction necessary?

Just use the standard for the answer...

4.2.1 The quality management system documentation shall include...d) documents, including records, determined by the organization to be necessary to ensure the effective planning, operation and control of its processes.

The correct answer is when the absence of them would not have an effect on effective planning, operation and control....

99.99999% of the answers people need are in the standard itself if they just look for them.
 
P

Polly Pure Bread

#29
Re: When isn't a Work Instruction necessary?

it can't be a requirement on an "if you need it basis".

It's either a requirement or it's not. The requirement is "documents", not work instructions. In many cases a bill of materials and/or a controlled drawing is enough.
If Work Instruction is not a document, please tell us what is it?
 

Randy

Super Moderator
#30
Re: When isn't a Work Instruction necessary?

it can't be a requirement on an "if you need it basis".

It's either a requirement or it's not. The requirement is "documents", not work instructions. In many cases a bill of materials and/or a controlled drawing is enough.
Better read this............

7.5.1 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,
.....b) the availability of work instructions, as necessary,


Work instructions are in fact documents and if one wants to press the issue they can.

You'll also lose if you try to use the argument against 4.2.1 d "as needed"...many an organization has fallen on that sword when ineffective control has been identified because of the lack thereof.
 
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