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Top 15 Standard Work Instruction Examples
By: Ben Baldwin
April 6, 2022
Have you been on the fence about integrating work instruction software into your operation? Or are you looking for new areas to go digital? Examples of standard work instructions help you understand the capabilities of the software while also bringing to light the variety of ways it can benefit your unique business.
No matter the process, we should remember one thing: a process is a process.
What I mean by this is that any process can benefit from digital standardization, dynamic interaction, and intelligent activities. Whether it be for assembly work, field service, or training the next generation of carpenters, standard work instructions benefit everyone.
With this in mind, let’s explore the top 15 standard work instruction examples with VKS. We’ll go through the reasons for using these guidebooks along with some helpful key takeaways and links to more in-depth discussions.
Let’s dive in!
- Assembly Instructions
- Troubleshooting
- Machine Set-Up & Changeover
- Workforce Training
- Lockout/Tagout
- Gemba Walk
- Packaging
- In-Line Quality Inspection
- Preventative Maintenance
- Health & Safety
- Final Inspection
- Cleaning Procedures & Validation
- Incoming Inspection
- Process & Environmental Audits
- Fabrication Procedures
Standard Work Instruction Example 1: Assembly Instructions
Assembly instructions can be fairly straightforward. The process is laid out in a linear step-by-step sequence and operators understand what they need to do from start to finish.
Companies leverage VKS to give their workers visual and interactive work instructions that guide employees through the major and minor production steps. Both within production lines and single-cell workstations, VKS assembly instructions ensure that workers are performing the right actions at the right time with the right knowledge.
On top of that, while operators are assembling their components, they are also able to interact with Smart Forms that help collect valuable production data.
- Standardize your best processes to increase efficiency and productivity.
- Integrate quality into every process with Smart Forms that capture critical inspection points.
- Track productivity and receive production data in real time.
- Connect with assembly tools and devices to automatically advance work instructions.
Standard Work Instruction Example 2: Troubleshooting
Our next work instruction example is for procedures that need to be responsive to multiple conditions in real time. Troubleshooting guidebooks provide instructions that are dynamic to the situation at hand. When processes follow a less linear format and need to change based on customer requirements, your operators are never left without the instructions they need.
VKS troubleshooting guidebooks use a powerful rule engine to change the instructions based on operator input. This means that both experienced and inexperienced employees solve complex problems and build intelligently with speed and confidence.
- Create dynamic best practices based on in-the-moment conditions.
- Enable every team member to intelligently solve complex problems.
- Use the VKS Rule Engine to automate notifications and required steps.
Standard Work Instruction Example 3: Machine Set-Up & Changeover
Modern machines are becoming incredibly complex. Adding to this, high turnover rates and the growing skills gap are leaving modern workers without the proper machine setup and changeover skills. Industries need employees that quickly act with experience.
But if they don’t have years of experience, how can this be done?
With standardized machine setup procedures that are created around the best practices of your company, you give your workers the required experience from day one of their careers. Integrate knowledge into your entire operation with well-laid-out plans that workers follow with confidence. Every operator is given precise instructions and process variations are practically eliminated.
- Safely set up machines and changeover production lines.
- Perform full pre-work inspections on equipment.
- Capture tribal knowledge and share best practices with other team members.
Standard Work Instruction Example 4: Workforce Training
When introducing new hires into the manufacturing environment, it is important to give them access to as much information as possible. Whether orienting workers in a classroom setting or performing on-the-job training, standard work instructions enable companies to easily pass on knowledge to the next generation of employees.
VKS enables manufacturers to create dynamic training guidebooks that fit the needs of evolving workforces. Add links to additional information so that even new operators always have access to key context and knowledge.
With VKS, no operator is left without direction!
- Facilitate classroom and on-the-job training with educational guidebooks.
- Provide easy access to additional information for those who need it.
- Track training qualifications for strategic workforce planning.
Standard Work Instruction Example 5: Lockout/Tagout
Lockout/Tagout procedures are an essential safety practice, making this work instruction example crucial for all operations with heavy machinery and specific guidelines surrounding them. Every team member depends on them being followed carefully and intelligently. When a machine or vehicle is locked out, several ignition/start-up points need to be disabled. If one point is missed, or if the tags are hidden, accidents are sure to happen.
With standard work instructions, make safety a key priority. VKS enables companies to create well-defined Lockout/Tagout procedures based on specific equipment requirements. This means that whenever an employee performs this process, you and your team can rest assured that the process was performed correctly.
- Standardize Lockout/Tagout procedures.
- Tailor instructions to specific machines and equipment.
- Use Smart Forms to verify proper Lockout/Tagout procedures were followed.
- Increase safety for every team member.
Standard Work Instruction Example 6: Gemba Walk
Gemba walks are an extremely effective method to gain insight into how processes are carried out within your operation. This is a time to talk, listen, and gather as much information as possible. But how will you store the information you are acquiring?
Leverage the capabilities of VKS to supercharge your Gemba walks with intelligent digital methods. Create a standard plan that you and your team can follow and never miss any key observation points. Then write notes, take pictures, and send valuable information directly within your VKS Gemba guidebook.
- Create and follow a defined itinerary.
- Use Smart Forms and integrated checklists to take detailed notes.
- Capture photos of issues and discrepancies directly within VKS.
- Send notes immediately to the appropriate leaders.
Standard Work Instruction Example 7: Packaging
Packaging your products is just as important as the products themselves. If your products are packaged improperly or are mislabeled, they could be damaged, misdelivered, or even lost. There should never be any guesswork when it comes to preparing your products for delivery.
Ensure proper packaging every time with detailed and focused packaging instructions. Assembly operators and packaging departments use checklists and step-by-step procedures to guarantee consistent deliveries!
- Eliminate guesswork when packaging your products.
- Ensure your customers receive their products the same way every time.
- Guarantee product safety during shipping.
- Track which items are ready for shipping in real time.
Did you know that Smith Induspac uses our work instruction software to standardize their packaging operation? From a wide variety of packaging needs, they deliver consistency and quality with every box delivered.
Standard Work Instruction Example 8: In-Line Quality Inspection
Even within automated production environments, regular inspections are key to maintaining a smooth operation. Often, workers will observe the production line and make adjustments based on current conditions.
This may not sound like a process that can be standardized, but I assure you it very much is.
With digital work instructions, set up timed actions that prompt users to check key systems, inspect quality, and collect data. While the production line is operating, workers use in-line quality inspection guidebooks to ensure quality is secured every step of the way.
- Mitigate risk through regular in-process inspections.
- Collect valuable data for quality assurance.
- Gather product samples for quality control.
- Monitor process health and Statistical Process Control (SPC).
Standard Work Instruction Example 9: Preventative Maintenance
Preventive maintenance is key to extending the life of your machines and decreasing machine downtime. But maintenance actions need to be done correctly. Otherwise, these actions could do more harm than good.
VKS preventive maintenance guidebooks provide operators with comprehensive and dynamic maintenance instructions. Like troubleshooting guidebooks, the instructions use an advanced rule engine that gives operators the proper instructions based on the situation at hand, making this work instruction example particularly powerful.
This means that more employees are empowered to carry out maintenance activities while also decreasing the effect of maintenance and downtime.
- Extend the life of your machines and equipment.
- Ensure proper preventative maintenance with step-by-step guides.
- Reduce downtime.
- Gain detailed maintenance history records.
Standard Work Instruction Example 10: Health & Safety
People are your most valuable resource. VKS Health and Safety guidebooks inform workers of proper health and safety practices while also making them aware of potential risks.
Place helpful reminders like PPE (Personal Protective Equipment) pictograms and ergonomic reminders within process instructions. At the same time, provide key standard work instruction examples for employees to review periodically.
Additionally, track safety/training qualifications to make sure that only qualified employees perform certain jobs.
With health and safety guidebooks that identify hazards and the correct safety actions, employees never miss key safety information. A little bit of knowledge goes a long way in keeping your employees healthy and secure.
- Create training and pre-work safety guidebooks.
- Track training requirements and qualifications for optimal safety.
- Confirm process comprehension with Smart Forms.
- Integrate health and safety pictograms when it matters most.
Standard Work Instruction Example 11: Final Inspection
Final inspections are your last point of contact with your products. So they need to be performed to exact standards.
The quality of your products is only as good as your quality inspections.
Take your final quality inspections to the next level with final inspection guidebooks. Provide workers with a thorough and systematic set of inspection points and instructions. This creates an inspection process that never misses key points.
With each inspection point, workers are collecting valuable data that can be used for quality assurance for the customer. Additionally, this data enables you to optimize production through pass/fail analysis while tracking consistency over time.
- Know what to look for with standardized critical inspection points.
- Take pictures to confirm the quality assurance.
- Capture key inspection data like dimensions, serial numbers, and more with checklists and Smart Form data.
Standard Work Instruction Example 12: Cleaning Procedures & Validation
Within pharmaceutical and food service environments, having the proper cleaning procedures in place is the number one method to prevent product contamination. Clear sequential cleaning instructions enable workers to never miss any substance or residue.
Use VKS to create step-by-step cleaning protocols that ensure cleaning is performed to exact standards every time. Use this information to also validate which pieces of equipment were cleaned and when.
- Provide workers with clear cleaning protocols.
- Track and validate when cleaning activities were performed and by who.
- Ensure that only qualified personnel perform high-level cleaning procedures.
- Use smart forms within VKS to make notes and take pictures for reference.
Standard Work Instruction Example 13: Incoming Inspection
As materials and parts enter your facility from external sources, you need to make sure that their quality meets your standards. By using visual work instructions and incoming inspection guidebooks, you can keep sub-par pieces at bay and decrease the rate of defects and re-work.
It’s vital that you catch inconsistencies and defects before they get to the shop floor.
- Consistently review the quality of products coming into your facility.
- Establish inspection frequencies and capture critical information from dimensions to visual inspections and more.
- Use the VKS Digital Ecosystem to standardize inspection processes and quality control plans with your suppliers.
- Control your supply chain's quality and update inspection procedures at the click of a button.
Standard Work Instruction Example 14: Process & Environmental Audits
Auditing is a key practice that enables companies to validate and guarantee compliance with internal and industry standards such as ISO 9001 and 14001.
Use VKS to standardize your auditing activities with interactive and intelligent checklists. Create a systematic review of any process by taking notes, pictures, and videos directly within VKS. Then share your observations with your team to implement improvements.
- Confidently perform audits regularly.
- Use Smart Forms to take notes and capture photos.
- Use SPC data points to track if processes are approaching tolerance limits.
- Send audit emails to the appropriate leaders directly within VKS.
Standard Work Instruction Example 15: Fabrication Procedures
Our last, but not least, work instruction example concerns fabrication. There is a lot that goes into taking raw materials and fabricating distinct components. From welding and deburring to grinding and testing, fabrication processes can be complex, to say the least.
Make sure that every process is performed correctly with digital work instructions. Keep track of complex processes while giving operators in-depth instructions that remove the guesswork.
For processes that require hands-free interaction with work instructions, such as welding and grinding, create timed steps that automatically advance to the next step without direct operator engagement.
- Use clear pictures to give operators visual quality cues.
- Create timed steps for quick hands-free step advancement.
- Integrate quality checks at key points in the fabrication process.
Limitless Possibilities
There are many more standard work instruction examples that we could list but with an endless amount of possibilities, you may never finish reading this article. So I’ll leave you with one final thought.
Any process can benefit from standardization, and standardization is enhanced by going digital.
If you’d like more information or want to take a deeper dive into how work instruction software can benefit your unique operation, book a demo today! Taking control of your operation is only a click away.