By Philip Sage

Work instructions are written documents intended to convey how to do a job.

They are an integral part of the process that begins with designing the maintenance strategy using RCM and ends with the execution of the work delivering value to the machine.

Just how important is it to develop and produce excellent work instructions?

As a simple thought – if our work instructions are poor, or if our training is less than adequate – we would “expect” our work execution to be less than 100%, and induce hidden failures and machine breakdowns in the future weeks.

Designing an experiment to measure the effectiveness of work instructions is a formidable challenge so when a chance to gain some insight into why this task is vital to your success, I will share a recent experience(experiment).

Recently I had the chance to interact with a talented team and discovered why work instructions often fail to produce the desired result – which I will call a “well executed job”.

The challenge was to build a software model of a very simple machine and predict its outcome.

To make sure the “work force” was well trained they participated in dedicated training for 12 hours to learn how to perform this task. All were “experienced” in their area of expertise, and familiar with the broader concepts.

Each participant was given a very detailed 5 page work instruction document.

The task was simple ->requiring each student to follow a written work instruction that was contained on the 5 pages – including exact screen shots of the finished product, and intermediate step results.

QA AUDIT:
The written work instruction also included screen shots of database view of the data required to be populated into the software model so the users of the document could self check their data input.

TIME PRESSURES:
To add some realistic pressures and increase the chance of human factors interacting with the exercise, a time limit was imposed of 1.5 hours.
The purpose of the exercise was to type the data into the software Just a step above data entry – reinforcing the previous training provided on how to utilize the software, and then build upon the base model to enhance some fundamental concepts about reliability.

 

About Philip Sage

SAP PM Expert - Design Architect of Green Field SAP and Reliability Plant. SAP MM QM, HR, PP extremely knowledgeable. Configured SAP DMS and integrated with SAP PM.

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