Digital Work Instructions Improve Standard Work in Manufacturing

“Why does Jane produce 50 units a day, but Bob produces 45 units a day?”

This type of question is all too common in mid-sized factories. Two factory operators could be building the same product but the output is variable. When operator training is inconsistent, documentation is on paper, and the only guide is the most tenured employee, the overall efficiency of the factory will be highly variable. 

 

Optimizing manufacturing operations starts with standardizing work and implementing digital work instructions. Though distinct, these two concepts, are closely related and work together to make manufacturing processes more efficient with less scrap and rework. Here's how they do it.

 

Understanding Standard Work: The Foundation of Consistency

At the core of every efficient manufacturing process lies standard work. This refers to the documented procedures that outline the best practices for performing specific tasks. Standard work ensures that every employee follows the most efficient and effective methods, resulting in consistent quality and output.

Standard work is more than just a set of instructions; it represents the accumulated knowledge and expertise within an organization. Manufacturers can minimize variability, reduce errors, and enhance overall productivity by adhering to these established processes. 

The Role of Digital Work Instructions: Bringing Standard Work to Life

While standard work provides the foundational content, the benefits of digital work instructions are that they bring these processes to life in a modern, interactive format. Digital work instructions are the digitized version of standard work, presented through devices like tablets or computers. They often include text, images, videos, and interactive elements that guide workers through tasks step by step.

Example of digital work instructions with layered content 

This digital approach offers several advantages:

• Ease of Updates: Digital work instructions can be quickly updated and distributed, ensuring all workers can access the latest procedures. This is crucial in fast-changing manufacturing environments.
• Enhanced Clarity: The inclusion of visual aids and interactive components makes complex instructions easier to understand, reducing the likelihood of errors.
• Batch updates for variations: Digital platforms can easily accommodate a high-mix manufacturing environment that requires process variants. 
  

Real-Time Feedback and Continuous Improvement

One of the significant benefits of digital work instructions is the ability to collect real-time data and feedback. As workers follow these instructions, the system can track their progress, identify bottlenecks, and highlight areas for improvement. This data-driven approach allows manufacturers to continuously refine their processes, leading to increased efficiency and reduced waste.

The real-time nature of digital work instructions also facilitates immediate updates when processes change, ensuring that standard work remains relevant and effective.

Enhancing Training and Onboarding

Training new employees or cross-training existing ones can be time-consuming and challenging, particularly in complex manufacturing environments. Digital work instructions simplify this process by offering an interactive and engaging learning experience. New workers can follow guided instructions with embedded simulations and other learning tools, helping operators become proficient more quickly.

This streamlined approach to training not only reduces the learning curve but also ensures that all employees are consistently applying the best practices defined by standard work.

Supporting Complex and Customized Manufacturing

In manufacturing environments where customization is frequent, or processes are particularly complex, digital work instructions provide a dynamic and flexible solution. Unlike static standard work documents, digital instructions can adapt in real-time to different product configurations or customer specifications. This flexibility ensures that standard work is applied accurately, regardless of the scenario, helping manufacturers maintain quality and consistency even in challenging situations.

A Synergistic Relationship for Better Manufacturing

The relationship between standard work and digital work instructions is a powerful one. Standard work lays the groundwork by defining the best practices for manufacturing processes, while digital work instructions enhance these processes by making them more accessible, interactive, and adaptable. Together, they help manufacturers achieve the efficiency, consistency, and quality needed to thrive in today's competitive landscape.

By embracing both standard work and digital work instructions, manufacturers can stay ahead of the curve, continuously improve their operations, and deliver high-quality products to their customers. Start using digital work instructions for free today.