1.4 Work Instructions & Visual Aids

Clarity through photos, diagrams, and exploded views.

Clear, visual instructions are the quiet engine of a stable box build—especially when a new operator starts at 6 AM and needs the next move to be obvious. A strong SWI (standard work instruction) sets one truth for each operation, pairing photos and simple diagrams with the essentials: tools, torque, labels, and checks. Tied to MES (manufacturing execution system), the right variant appears at the right moment, while safety cues like PPE (personal protective equipment) and ESD (electrostatic discharge) states stay front and center. Exploded views and routing maps turn tricky sequences into repeatable motions without paragraph-hunting. Change control through ECN (engineering change notice) keeps every screen and print aligned to the latest design. The result is fewer guesses, cleaner audits, and a line that moves with calm, predictable rhythm.

1.4.1 Purpose (why this matters)

A good SWI (standard work instruction) makes the next move obvious, even for a new hire on Monday at 6 AM. It removes guessing, blocks common mistakes, and lines up with MES so the right variant, torque, label, and test show up at the right minute.

Rule: one truth, one click, one page per operation.

1.4.2 Anatomy of a great SWI (what to include)

Section	What it shows	Must-have details
Header	Operation ID, PN–Rev, Variant	Takt target, safety/PPE icons, required ESD state
Prereqs	What must be ready	Kit check, tools/dies, torque driver IDs, consumables lots
Tool/parts box	What you’ll touch	Photo/outline of parts, fastener IDs by torque group, adhesives/TIM kit
Steps (1 page)	Do this → check → next	Numbered steps with photos/diagrams, pin-1/latch arrows, “Do/Don’t” in the margin
Quality checks	What “good” looks like	Go/no-go gauges, torque values, label position ± mm, gasket compression cues
Variant flags	A/B/C differences	Colored badges on steps; hide/show by MES selection
Exit criteria	Done = allowed to proceed	Green boxes: “Torque recorded,” “TPA engaged,” “Label scanned,” “Test result attached”

Keep each operation on one screen (scroll minimal). Long tasks → split into sub-ops.

1.4.3 Photos & diagrams (make the image do the talking)

Lighting & background: diffuse light; matte background; avoid black-on-black (use colored mats).
Angles that teach: show the hand position, not just the part; shoot square to surfaces to avoid illusions.
Callouts: arrows for pin-1, gaskets path, bead direction, airflow. Add a scale (small ruler) when size matters.
Before/After tiles: left = wrong, right = right (e.g., shield pigtail >10 mm vs ≤10 mm).
Exploded diagrams: simple line art for stack order; each fastener labeled by PN + torque.
File discipline: name assets by OpID_Step_Variant; keep an image vault tied to the drawing rev.

1.4.4 Exploded views & routing maps (fit, order, path)

Exploded views: show sequence (1→2→3), standoff heights, washers/spacers, threadlocker color, and torque values grouped by icon/color.
Routing maps: centerline path, clamp icons, first-bend position, min radius, shield bond points, and label locations with ±5 mm.
Call gaskets clearly: start/stop marks, corners, compression checks; note scrape points for paint where EMC bonds.

1.4.5 Variants without confusion

SWIs filter by scan (SKU/Variant). Only the relevant steps appear.
Badges (A/B/C) on any shared page; color-coded consistently plant-wide.
If steps diverge >30%, separate pages—don’t bury “if A then…” in paragraphs.
Label maps and accessory lists follow SKU; block start if the kit doesn’t match.

1.4.6 Digital delivery (station UX that helps, not nags)

MES tile: zoomable images, 10–30 s video clips for tricky motions, and a checklist with green ticks.
Hotkeys/foot pedal to advance when hands are full.
QR on fixtures opens the exact op; no USB sticks.
Localization: language toggle; minimal text + icons; metric units.
Offline fallback: cached SWIs print with rev & QR—and auto-expire when a new rev arrives.

1.4.7 Torque, adhesives & TIMs (show the amount, not just the idea)

Torque map snippet on the step; bits by ID; add a witness mark example.
Threadlocker: dot size photo; color vs chemistry; cure notes.
TIMs: bead diameter gauge image, pattern (X/lines), “too much/too little” examples; pad locations ghosted on the chassis.

1.4.8 Labels & regulatory marks (straight, legal, repeatable)

Label map: ghosted outlines, datum edge, alignment ± mm and angle.
Surface prep icon (wipe/apply); squeegee strokes; bubble-free example.
Dynamic fields (SN, MAC, keys) come from MES; SWI shows where, not what to type.
Regional marks (CE, UKCA, etc.)—variant-filtered so the wrong region can’t appear.

1.4.9 Accessibility & readability

Font ≥ 10 pt at arm’s length; color contrast high.
Replace jargon with icons (pin-1 triangle, gasket path, airflow arrow, shield clamp).
Safety: glove/ESD/eye icons where needed; no wall of text.

1.4.10 Change control & feedback

SWIs change only via ECN. Change bars highlight what moved.
Redline tool at the station: operators can suggest with a photo; PE reviews within 24 h.
Quarterly refresh of critical photos (new fixtures, new parts finish).
Training mode: same SWI with extra “why” panels for onboarding.

1.4.11 Common traps → smallest reliable fix

Trap	Symptom	Fix
Tiny text, busy pages	Questions, slow builds	One page per op, 10 pt font, more pictures
Photos with glare or black-on-black	Missed features	Diffuse light, colored mat, edge highlights
Unlabeled fasteners	Wrong screw/torque	Fastener photos with PN + N·m; color torque groups
Perspective lies	Crooked labels, misaligned parts	Add datum lines and rulers; square camera
Variant in paragraphs	A builds like B	Variant badges and MES filtering
SWI ≠ BOM	Missing parts	SWI pulls MBOM line numbers; sync via MES
Stale printouts	Hidden rev drift	QR + rev watermark; prints auto-expire

1.4.12 Pocket checklists

Authoring

Header complete (PN–Rev, Variant, takt, PPE)
Tool/parts box with PNs and torque bits
Steps: numbered, clear photos/diagrams, pin-1/latch shown
Quality: gauges, ± mm label positions, torque & checks
Variant badges and MES filters set; video for tricky moves

Peer review (10 minutes)

Build the step from the SWI only; time it
Find one potential error—fix the image, not the paragraph
Verify MBOM line links; torque/specs match map

At the station

Scan → correct Variant SWI opens
Images readable at arm’s length; zoom works
Exit checks tick green before next op

Bottom line: show the next motion and the proof—not an essay. With clean photos, honest diagrams, torque and label maps baked in, and variant-aware delivery from MES, your work instructions become quiet guides. People stop guessing, defects fall, and the box build flows.