Today Electronic Work Instructions Software Is Instrumental

Today Electronic Work Instructions Soft Ware Is Instrumental To The

Today, electronic work instructions soft- ware is instrumental to the shop floor. And market leaders are investing in the integration of electronic work instructions (EWIs) with 3D visualization and simulation soft- ware, so operators aren’t just following along with instructions, they’re able to view animations of each step and sometimes even improve things right on the spot. Here’s what you need to know about the past, present, and future of electronic work instructions in manufacturing operations management, as well as discuss eight ways they’re transforming the shop floor. From paper-based to next-generation It’s vital that you have clear and repeatable instructions for every manu- facturing process.

Traditionally, shop- floor workers would hang laminated pieces of paper on the wall with dia- grams and explanations of each step. The shortcomings of this are obvious, particularly when an engineering change order (ECO) was required and those changes needed to be sent to engineering, revamped, sent back to manufactur- ing, reprinted, relaminated, and so on. If we’re talking about a global operation, this becomes even more of a challenge. The more complex something you’re building is, generally the more com- plex those instructions have to be, and a paper-based approach can be limiting. But computer technology on the shop floor wasn’t always as easily accessible and widespread as it is today.

Since document control software has become widely adopted, however, EWIs have made their way into the manufactur- ing environment. EWIs have improved the way supervisors and operators build products, and the way they interact with engineers and maintenance personnel. The technology enables a centralized, standardized, and automated document management system, and can be found on most modern manufacturing shop floors. In addition to improving communica- tion and collaboration on the shop floor, streamlining EWIs mitigates many of the traditional risks associated with changing a work order. In the past, an engineering change may have been ordered, but never completed or at least never communi- cated to the appropriate personnel once completed.

With automated workflows, notifications can be triggered to ensure the process is completed and the appro- priate personnel are notified. Workflows can also ensure that the right instructions are being followed on time and in the context of the manufacturing process. As the use of simulation and 3D visual- ization software becomes more prevalent, moving from engineering onto the shop floor, EWIs are becoming an even more effective tool. By integrating EWIs with this technology, an operator can watch each step of a process played out via animations. In some cases, operators and supervisors are trained to actually make changes and improvements to these processes in real time rather than waiting for an ECO.

With the continuous advancement of technology, we expect to see further integration between plant and process design, 3D visualization, simulation soft- ware, workflow software, manufacturing execution systems, and electronic work instruction software. The role of EWIs Increasingly, modern manufacturing operations management (MOM) plat- forms offer EWIs as an application within a broader portfolio of applications that integrate via the same software platform. INfOCUS 8 ways electronic work instructions are transforming the shop floor By Mike Roberts, LNS Research PLE1311_INFOCUS_V5msFINAL.indd 16 11/14/13 10:50 AM Standardization on the MOM platform facilitates the sharing of information and workflows, and is often a driver of great- er collaboration capabilities in globally distributed manufacturing environments and even between functional units.

Eight benefits of EWIs Moving from paper-based work instructions to EWIs, there are many benefits. When accounting for the centralization, standardization, and automation capabilities offered by today’s MOM software platforms, those benefits increase dramatically. Below are eight ways EWIs are improving shop-floor operations and making manufacturers more effective: 1. Reduced downtime: Because com- munication is easier with an electronic routing and delivery system, less time is required to take maintenance actions or make engineering change orders. 2.

Stronger communication: A cen- tralized document management system enables greater ability to share docu- ments within the manufacturing envi- ronment, across facilities, and between functional units. Stronger communica- tion creates fewer errors. 3. Closed-loop manufacturing and quality processes: With a centralized platform, EWI/ECO content and data can be more easily shared with correc- tive and preventive action management and audit management processes. 4.

Closed-loop manufacturing and engineering processes: With a central- ized platform, EWI/ECO content and data can be more easily shared with the failure more and effects analysis processes. 5. Reduced waste/scrap: The ability to communicate and collaborate with engineering more effectively helps to improve first-time quality and reduce waste in the manufacturing environment. 6. Easier communication of regula- tory changes: Because many industries face dynamic regulatory environments, EWIs help to quickly communicate changes required for shop-floor processes and validate that personnel have been made aware of and are following them.

7. Faster new product introduction process: Streamlining communication and collaboration between manufacturing and engineering reduces the time required to develop, test, and build new products. 8. Reduced risk and improved effi- ciency: With automatic notifications triggered for both shop-floor and engi- neering workers, the likelihood of a non-conformance or compliance issue is much lower. PE Mike Roberts is a research associate at LNS Research.

As part of the 2014 Global Auto-mation & Manufacturing Summit, Control Engineering and Plant Engineering are looking for manufac- turers who want to share their success stories with a global manufacturing audi- ence. They are issuing a Call for Pre- sentations for the 2014 Summit. Control Engineering and Plant Engi- neering, in partnership with Hannover Fairs USA, will present the 2014 Global Automation & Manufacturing Summit on Tuesday, Sept. 9, 2014, at the Industrial Automation North America Show, part of IMTS 2014 in Chicago. Building off the success of the inau- gural 2012 event, the 2014 Global Automation & Manufacturing Summit will feature success stories from manufac- turers around the country.

Submissions for presentation can include Word documents, videos, Power- Point presentations and any other con- tent you think will be helpful in evaluat- ing your plant for inclusion in the 2014 Summit. Go to summit for the form to submit to your proposal today. Proposal submissions are due by Dec. 20, 2013. Tell your plant’s success story at 2014 event PLE1311_INFOCUS_V5msFINAL.indd 17 11/14/13 10:50 AM

Paper For Above instruction

Electronic Work Instructions (EWIs) have become a transformative tool on the manufacturing shop floor, significantly improving operational efficiency, communication, and flexibility. Transitioning from traditional paper-based instructions, EWIs leverage digital technology to ensure that manufacturing processes are standardized, easily updated, and accessible across geographically dispersed facilities. This essay discusses the evolution, current applications, and future prospects of EWIs, emphasizing their role in enhancing production workflows and reducing operational risks.

Historically, manufacturing instructions were documented on laminated paper, often manual and static, which posed challenges during necessary updates, such as engineering change orders (ECOs). Such paper-based systems were cumbersome, particularly in complex global manufacturing environments where changes needed to be communicated swiftly and accurately. The advent of document control software facilitated the adoption of EWIs, enabling centralized, standardized, and automated document management that improved communication and collaboration on the shop floor. EWIs not only replaced paper instructions but also introduced automation in workflow processes, allowing for notifications, approvals, and real-time updates that mitigate errors and delays.

One of the most notable advancements in EWIs is their integration with 3D visualization and simulation software. These technologies allow operators and supervisors to view animated steps of a manufacturing process, enhancing understanding and enabling on-the-spot improvements. The visualization capabilities help bridge the gap between engineering design and shop-floor execution, fostering a more interactive and dynamic environment. Consequently, operators are increasingly trained to make real-time adjustments, reducing dependency on ECOs and accelerating the production cycle.

The progression of EWIs is closely tied to the evolution of Manufacturing Operations Management (MOM) platforms. Modern MOM systems embed EWIs as integral components, facilitating seamless data sharing, workflow automation, and collaboration across disparate units and locations. This integration not only streamlines operations but also enhances quality by enabling closed-loop feedback where data from manufacturing processes inform continual improvements. For instance, data from EWIs can be linked with quality management systems to promptly address defects, thus minimizing waste and wasteful rework.

There are several key benefits associated with the adoption of EWIs in manufacturing. Reduced downtime is achieved through faster communication and streamlined change management. Stronger communication channels ensure that all personnel are updated on procedural revisions and regulatory changes promptly. Additionally, EWIs support faster new product introduction by simplifying and expediting the coordination between engineering and production teams. They also significantly improve compliance with industry regulations by providing clear, accessible, and up-to-date instructions, which are vital in highly regulated sectors such as aerospace, automotive, and pharmaceuticals.

Furthermore, EWIs contribute to sustainability efforts by reducing paper waste and promoting digital documentation, aligning with environmentally conscious manufacturing practices. They also promote a safer working environment by providing consistent and clear instructions, thereby decreasing the likelihood of errors and accidents on the shop floor.

Looking ahead, the future of EWIs revolves around further integration with digital twin technology, augmented reality (AR), and artificial intelligence (AI). Digital twins can simulate entire manufacturing processes, allowing EWIs to be dynamically updated based on real-time plant data. AR devices can overlay instructions directly onto operators' visual fields, improving ergonomics and responsiveness. AI can analyze vast datasets collected during manufacturing, offering predictive insights and recommendations for process improvements. These innovations will foster a more autonomous and intelligent manufacturing environment, further reducing risks, enhancing productivity, and supporting Industry 4.0 objectives.

In conclusion, electronic work instructions are reshaping the manufacturing landscape by transforming traditional, error-prone, and static paper-based procedures into dynamic, integrated, and highly accessible digital workflows. Their ability to facilitate rapid updates, improve communication, and support continuous improvement positions EWIs as essential tools for modern manufacturing enterprises aiming for operational excellence and innovation.

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