Minimize Waste

Our operation instructions give the users standard work practices in a visual way. While generally created for manufacturing work, instruction formats which include visual aids can be utilized by laboratories, service providers, end-users and the like. For knowledge transfer purposes, it is essential that procedures perfected by veteran employees correctly be passed on to next generation workers.

Problem

Workers in an automotive parts manufacturing facility were making packaging errors that resulted in charge-backs from the OEM, additional mandatory inspections and rework.

Solution

Poster-sized operation instructions that clearly documented standard best practices were hung in each work cell.

  • Waste was greatly reduced.
  • Secondary inspections were eliminated.
More

Problem

Our glass manufacturing client was losing veteran employees and needed accurate knowledge transfer of procedures so the new employees were properly trained.

Solution

Working side by side with the exiting employees, we captured their experience and steps and explained them visually in manufacturing work instruction format. These were used to

  • Efficiently train new employees
  • Effectively retain product quality

Knowledge Transfer of Veteran Employees’ Procedures
For Next Generation of Workers

Problem

Because many operators in this food processing facility had English as a second language (ESL), they could not comprehend text-heavy standardized work instructions.

Solution

With illustrations explaining the process, ESL operators could understand and perform the work correctly. In addition,

  • Performance improved for workers of all languages.
  • Translation costs were reduced (fewer words, lower costs).

Visual work Documentation Eliminates Language Barriers

Problem

Operators at our client’s aerospace facility could not pass a certification test for starting a line.

Solution

We distilled the pertinent information necessary and provided it in a user friendly format that workers

  • Used as a study aid to pass the test
  • Used as an on-the-job quick-reference set of operator instructions

Operation Instructions Used as Study Aids and Job Aids

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