Issue link: https://iconnect007.uberflip.com/i/1464867
36 PCB007 MAGAZINE I APRIL 2022 cient. For the work instruction and process to work cohesively, we must combine the task with the surrounding environment, tools, and space. is requires looking at it from a higher level. To begin with, we must evaluate the space. Is the machine or tool placed efficiently? Are there any hazards due to the installation? ese could be: • Tripping hazards • Crush or pinch hazards • Ergonomic hazards One thing that is overlooked when installing new processes and/or equipment is the impact the work area has on the success of the process. If we don't look at these things, we are creating waste. In this context I do not mean waste or scrap of the product but the waste of time due to poor planning of the space. We need to look at items such as: • Tools required for the task • Movements the operator must make • Travel if the operator must move the product to and from the machine • Health and safety such as liing and twisting, if so applicable is is where the importance of combining the process or work instruction with efficient development of the workspace or cell comes in. Another important aspect is to optimize the workspace so that it only contains the tools and supplies needed for the task. Get rid of everything else which serves no purpose and just creates clutter. Time to Test Here is where involving an operator-level employee benefits the overall success. Once the process or work instruction is documented, it must be tested. Go through the steps one by one to validate the necessity. You will find that some of your requirements may be dumb. Dur- ing this evaluation you will be able to optimize the steps, validate the ergonomics of the area, and streamline movements to achieve the best possible outcome. It is only aer this is complete that you can effectively train your workforce. ey will learn the task based on optimal efficiency and the repeatability will be higher than that of a loose or messy process. e thing is, if you leave holes or gaps in a process, your operators will find the shortcuts or ways to deviate from the intended task. Having a robust and tested process, as well as work instruction, will keep this behavior to a minimum. Now that we have our employees trained, we need to document this to be compliant to the QMS. Many times, we train the employees, doc- ument their file as trained, cut them loose, and they disappear into the abyss. Well, that doesn't work either. Once the employee is trained and documented, they need to be reviewed on a reg- ular basis. Most common is an annual review. is ensures they are still performing the task correctly and/or have improved or degraded since last review. Because the QMS needs to be reviewed at least yearly, it gives the department an opportunity to review the process as well. Perhaps the machine was upgraded. Perhaps there is an obsolete step or a new one required. is is all part of the overall continuity between the process, work instruction, and employees performing the tasks. Conclusion e process must be designed optimally, including workspace, tools, and ergonomics. In today's times, efficiency, repeatability, and the minimization of waste is crucial. When pro- cesses and work instructions are "in tune" the ability to efficiently increase productivity and quality will quickly become apparent. PCB007 Todd Kolmodin is VP of quality for Gardien Services USA and an expert in electrical test and reliability issues. To read past issues or contact Kolmodin, click here.