Work Instructions Example: Integrating Visuals into Work Instructions

For decades, manufacturers across industries have used work instructions that relied too heavily on text, making them dense and convoluted. But today, in our incredibly visual modern world, including high-quality visuals to complement and enhance text is critical.

By integrating visual elements such as diagrams, photographs, color coding, and infographics into work instructions, manufacturers can significantly improve comprehension and reduce errors, making it easier for workers to follow procedures accurately and efficiently.

Understanding Visual Work Instructions

Visual Work Instructions (VWI) are dynamic guides that use text, images, 3D models, 3D animated sequences, and real-world pictures and videos to communicate complex processes to anyone and everyone across production. Modern VWIs combine technical data and visual information to enhance understanding, reduce errors, and simplify communication.

And it makes sense. Instruction manuals that include CAD models, drawings, and other relevant product manufacturing information (PMI) are much easier to read and understand. 

Key Components of Effective Visual Work Instructions

The visuals in a VWI must contain several key components to be effective. First, authors of Visual Work Instructions must use 3D visualization with relevant product manufacturing information (PMI) and animated sequences to illustrate each step effectively. These visuals must also be easily accessible and readable on a laptop, mobile device, tablet, or touch screen on the shop floor. 

It is also critical to establish a consistent use of symbols and color coding used by your entire manufacturing team. Authors, engineers, and operators should be well-versed and able to decode symbols and understand color codes easily. 

Visual Work Instructions Examples: Best Practices

When creating and implementing Visual Work Instructions, there are several best practices that enhance clarity and efficiency. An author's goal is to design instructions that are not only easy to follow but also improve overall productivity. Follow these examples.

1. Carefully plan the layout before adding any essential information. Use a clean, uncluttered design that allocates enough space for text and images. Establish a visual hierarchy with headings, subheadings, bullet lists, and numbered points. Maintain consistent fonts, colors, and symbols throughout to create a cohesive, easily-readable appearance.
   
   
2. Conduct a thorough text analysis. Break down each task into individual steps that align with the actual workflow on the manufacturing floor. Identify and include each step's key actions, materials, and tools.
   
   
3. Use a tool that understands the design intent and product manufacturing information (PMI) embedded in your 2D and 3D CAD designs. Look for one that can natively load your CAD files and streamline the process for your authors. Create additional views and add text, leaders, and animations that support the manufacturing process.
   
   
4. Ensure access and understanding across all teams. As discussed earlier, use universal symbols and color codes to help all team members understand the instructions. You'll also want to carefully consider your font and text size and include alternative text descriptions and audio instructions to make the instructions accessible for all.
   
   
5. Regularly review and update your Visual Work Instructions. Processes, equipment, and safety protocols all undergo semi-regular changes. So should your work instructions. Keep your Visual Work Instructions up-to-date so your employees are all on the same page.

Case Studies / Examples: Successful Implementation of Visual Work Instructions

It's one thing to consider effective Visual Work Instructions in theory. But how does this play out in the real world? Let's take a look at how including visuals in their work instructions significantly impacted Toyota's and Siemens production lines. Here are a couple of examples.

Toyota Motor Corporation

Manufacturing cars requires highly complex assembly processes, and Toyota was experiencing frequent errors on the production floor. This was compounded by its diverse team with varying levels of experience and language proficiency. The company needed to ensure consistent quality and improve its adherence to strict safety protocols.

Toyota turned its attention to the foundation of its manufacturing processes: Work Instructions. They developed detailed Visual Work Instructions using high-quality images and diagrams. The company standardized its visual symbols and color codes to indicate different actions and safety warnings. It used digital platforms to make visual instructions accessible on tablets and monitors at workstations. Toyota then trained its employees to use the updated Visual Work Instructions effectively.

And it paid off. Toyota saw a significant reduction in assembly errors and rework. Their workers' productivity increased, while they also maintained a higher level of quality and consistency.

Siemens

Siemens is a multinational technology conglomerate with varied manufacturing processes across different product lines. It constantly needs to train new employees while maintaining high standards of quality and efficiency. 

To support its various product lines, Siemens developed modular Visual Work Instructions that could be easily updated and customized for different products and processes. Like Toyota, it incorporated standardized visual symbols, color codes, and interactive elements to make instructions universally understandable. Siemens also leveraged digital platforms to distribute Visual Work Instructions to all employees easily.

By updating its Visual Work Instructions, Siemens improved consistency and quality across its different product lines. Even more, the VWIs allowed them to reduce training time and costs while increasing employee confidence, competence, and productivity.

Conclusion

When production happens between multiple teams across multiple divisions to create high quality innovative products, companies need robust, flexible tools that streamline processes and enhance collaboration. That's where Anark comes in. 

Our technology complements traditional systems, and also provides visual context for the most intricate manufacturing steps. We offer manufacturers the ability to create high-quality Visual Work Instructions—and then to easily collaborate and communicate in real time in one centralized system.

Consider revamping your own work instructions, and request a demo from Anark today.