‍Limitations of Traditional Methods for Work Instructions

Traditional work instructions can be dense and text-heavy, making it hard to reference quickly and easy to misinterpret. 

Drawbacks of Paper-Based Work Instructions

Paper-based work instructions often fail to align with the changing needs of the factory floor. This misalignment results in restrictions that can consume your valuable time. 

Here are some key drawbacks:

• Lack of Traceability: Paper instructions do not support data collection or monitoring. In modern manufacturing, traceability is crucial for continuous improvement. Without the ability to track actions, it can be challenging for you to measure performance or plan necessary improvements.
• High Risk of Errors: Managing work instructions, packaging, labeling, and complex diagrams on paper can be overwhelming for your team. This increases the risk of mistakes. For example, an incorrect step in assembling a product can lead to defects and costly rework.
• Difficulty in Updates: Updating paper-based instructions is labor-intensive. This is because any change in equipment or regulations requires you to produce new instructions, reprint, and redistribute them. This process can delay training and increase your costs, presenting outdated visuals to the technicians.
• Limited Mobility: Paper reliance requires mobile workers to travel back and forth to collect and drop off paperwork. This not only adds significant costs but also wastes time. For instance, a technician may need to visit the office multiple times a day to pick up new instructions or submit completed tasks.

Inefficiencies of Current Manufacturing Processes

Industries That Benefit from Digital Work Instructions

Relying heavily on traditional methods can introduce several inefficiencies in your manufacturing operations. Here is a quick run-down of things that might be signaling the need for a shift to work instructions:

• Lack of Standardization: Outdated or ineffective documents can cause inconsistent quality control and poor knowledge retention within your team. As a result, your field technicians might rely on outdated information or make educated guesses instead of following approved standards, resulting in variations in product quality.
• Costly and Time-Consuming: Changing or updating traditional work instructions is both expensive and time-consuming. In the manufacturing industry, there can be high costs and risks associated with outdated instructions remaining on the factory floor.
• Limited Scope: Paper instructions are limiting, especially when you are dealing with a wide range of product variants. In a configure-to-order environment, creating accurate paper instructions for every specific order becomes nearly impossible, leading to inefficiencies and potential errors for your business.

Importance of Digital Work Instructions in Manufacturing

Digital work instructions offer clear, contextual guidance, reduce errors, and improve overall business productivity. 

Let’s explore how they make a difference:

• Enhancing Skill Development and Knowledge Sharing: Digital work instructions provide clear, step-by-step guidance, making it easier for employees to perform tasks correctly. For instance, if you employ augmented reality-enabled training, it can help new hires get up to speed quickly, reducing their time to productivity. These tools also minimize cognitive load, allowing your workforce to focus on the task at hand without being overwhelmed by complex procedures.
• Improving Quality and Reducing Errors: Up-to-date digital instructions ensure that your team always has the latest information. This reduces the likelihood of mistakes and contributes toward product quality. For example, if a new assembly method is introduced, digital updates can be instantly shared across the team of technicians so that everyone is on the same page. Additionally, digital work instructions also support real-time insights from the production floor that help identify areas for improvement, leading to continuous process optimization.

Upgrading to HoloLens 2

Seeing the benefits of AR, Boeing decided to upgrade to Microsoft HoloLens 2, which offers greater positional accuracy and more advanced features. This upgrade allowed Boeing to:

• Expand AR-Guided Functions: Beyond wire assembly, AR is now used for equipment-rack installation and inspecting automated drilling procedures. These additions have broadened the scope of AR applications within Boeing's manufacturing processes.
• Deploy AR Across More Facilities: AR is now utilized in 15 global facilities, demonstrating Boeing's commitment to leveraging advanced technology for improved efficiency and accuracy.

Results and Impact

The results of implementing work instructions with AR have been significant for Boeing:

• 88% First-Pass Accuracy: Boeing witnessed that 88% of tasks were completed correctly on the first attempt, reducing the need for rework. This high level of accuracy not only improves operational efficiency but also contributes to higher product quality.
• 20% Reduction in Task Time: Tasks were completed 20% faster, leading to significant time savings and increased productivity for Boeing.

Key Lesson

A key lesson from Boeing’s experience is the smooth deployment of AR systems.

Boeing Senior Manager Randall MacPherson mentions, “Wearable technology is helping us amplify the power of our workforce.”

AR reduced job strain and made it easier for Boeing's technicians to adopt the new technology. This approach also minimized the typical resistance associated with new technology implementations in enterprise settings.

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