How things are actually made.
WHAT TO DOCUMENT
The process, step by step Settings and parameters Quantities and timings Quality checks at each stage What to do when something is wrong
WHY DOCUMENT IT
Production held in people's heads is inconsistent and it leaves when they do.
WHAT MAKES DOCUMENTATION USABLE
Written for the operator Available at the machine Short and specific
WHAT TO ESTABLISH
That the documented process is the actual process.
WHY
Aspirational documentation is ignored and it undermines everything else.
WHAT TO RECORD DURING PRODUCTION
Batch or run identifier Inputs used, with their batches Settings Output quantity Operators Time Any deviation
WHY DEVIATIONS
They explain quality problems and they are otherwise forgotten.
WHAT SETUP AND CHANGEOVER CONSUME
Time in which nothing is produced.
WHY IT MATTERS
Frequent changeovers reduce effective capacity substantially.
WHAT TO DO
Group similar work, and reduce setup time deliberately.
HOW TO REDUCE IT
Prepare everything before stopping Standardise tooling Establish a defined changeover procedure
WHAT TO MEASURE
Setup time, and improve it.
WHAT TO ESTABLISH
That process changes are authorised and documented.
WHY
Undocumented changes produce problems nobody can explain.
WHAT TO REVIEW
The process, against actual practice, periodically.
