- By Anthony Borges
- June 05, 2024
- Feature
Summary
Integrating Standardized Work Instructions (SWIs) onto the shopfloor leads to improved manufacturing consistency, quality, efficiency, safety, compliance and training effectiveness.
Manufacturers not using SWIs today for work and training rely on paper documented historical knowledge and workforce know-how, leaving them open to knowledge transfer losses when documents are misplaced, or not kept up to date, and when senior workforce experts leave or retire.
If work instructions are not detailed enough or are presented in a document that is out of date, errors are created, or critical steps are missed. SWI’s are kept updated on-the-fly, they are saved by the operator as tasks are completed, and instantly available for supervisory review ensuring the job’s progress status or its completion.
Further, workforce training is improved as tutorials or action steps are delivered in a step-by-step sequence; and with safeguards in place to protect from errors occurring, whereas the task must by completed as described, without error and ultimately with the users sign-off, directly linking who performed the task, at what time and to what extent of quality.
SWIs are integral for continuous improvement in manufacturing for several key reasons
Establishing baseline standardsStandardized work instructions define the best-known method for performing a particular task or process. They provide a baseline standard against which performance can be measured and improvements can be made.
Promoting consistency and quality
By ensuring that all employees follow the same standardized procedures, these instructions promote consistency in output quality. Consistent processes lead to predictable results, making it easier to identify deviations and areas for improvement.
Facilitating training and onboarding
Standardized work instructions serve as valuable training materials for new employees and provide guidance for existing workers. They help ensure that everyone understands expectations and performs tasks correctly, leading to higher levels of efficiency and productivity.
Enabling continuous monitoring and feedback
With standardized work instructions in place, manufacturers can continuously monitor performance against established standards. Feedback mechanisms allow for the identification of deviations and opportunities for improvement in real-time.
Fostering a culture of continuous improvement
Standardized work instructions create a framework for identifying inefficiencies and suggesting improvements. They empower employees to contribute to the continuous improvement process by providing a clear reference point for identifying areas in need of optimization.
Supporting lean manufacturing principles
Standardized work instructions align with Lean Manufacturing principles, such as waste reduction and value stream mapping. They help streamline processes, eliminate non-value-added activities and optimize workflow efficiency.
Driving operational excellence
Over time, continuous improvement efforts guided by standardized work instructions lead to increased operational excellence. By systematically addressing inefficiencies and implementing best practices, manufacturers can achieve higher levels of productivity, quality and customer satisfaction.
Software products like ShiftWorx include work process templates that are designed for timely, repeatable work–instilling workforce accountability that maximizes error reduction. SWIs and manufacturing Standard Operating Procedure (SOP) documented instructions enable workers to perform routine manufacturing tasks accurately.
Because SWIs are digitized, they are accessible from the cloud on any web browser on any device–their usage is unlimited, although common shopfloor documents include:
- SOPs
- Checklists
- Templates
- Images and Videos
- Work Instructions
- Safety Inspections
- Training Tutorials
- Web links
About The Author
Anthony Borges, director of Marketing, FreePoint Technologies Inc., offers more than 15 years of manufacturing optimization knowledge, with an aptitude for solving problems which increase manufacturing efficiency. He has successfully provided solutions to various multinational manufacturers involving the latest technology in sensors, laser (detection, measurement, welding, cutting and marking systems), PLC, machine vision, microscope and software solutions.
Headquartered in London, Ontario, Canada, FreePoint services various industries internationally, including leading automotive, aerospace, food processing and heavy industry clientele.
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