Manufacturing Work Instruction Template Case Study

United Plastics Group, Global Manufacturing Company

Client Problem:

As UPG improved its capabilities and manufacturing processes they needed to rollout a new set of Work Instructions to a number of plants around the globe. First they needed to settle on a manufacturing work instruction template to capture the critical steps in their best practices. Then they needed a way to upgrade all of the SOPs and develop the appropriate training, work instructions and work instruction templates to support the most efficient implementation. The timeframe for accomplishing this task was very short and the resources were limited.

Solution:

UPG chose ExpressTrain (and the SOP Express) as the single-source manufacturing work instruction template to capture the critical steps in their best practices. Then they needed a way to upgrade all of the SOPs and develop the appropriate training, work instructions and work instruction templates for writing the improved work instructions and as the basic platform for developing all the associated training and work instructions needed. By working with Princeton Center consultants UPG was able to create a customized version of ExpressTrain outputs to fit their needs. ExpressTrain was used to create the work instruction Master Document, visual quick reference cards, online job aids, Instructor-led Training PowerPoint slides, and Web-based Tutorials and standard operating procedures to support the most efficient implementation.

Financial Impact:

UPG was able to roll out the latest set of manufacturing work instructions (using the ExpressTrain work instruction templates), and deploy the new standards across the globe in a matter of months. The Development saved over 75% of the cost and time by using ExpressTrain, and the total financial impact of having all the plants following the corporate standard for Work Instructions is expected to be significant.

Summary:

• Utilization of write-once use-many single-source database
• Establishment of a corporate standard for work instruction templates
• Ability of key staff to create training materials at the Desktop
• Deployed consistent and concurrent content to all plants around the globe
• Provided supervisors and super-users with knowledge assets on demand