How to keep manufacturing personnel interested?

[karen_otto -at- agilent -dot- com]

Hi all,
Here's a problem I wanted to get your input on:
We have a number of assembly personnel (>300 on multiple shifts) who have a
job of following build instructions. Build instructions are usually notes in
a column of a spreadsheet that indicate how to put a particular part into a
circuit board.
The original intent of this column was to give only special build
instructions. The content of this column, however, has degenerated. Now
between 1/3 to 1/2 of the 20,000 instructions are variants of "insert part
and solder." This instruction is NOT a special instruction - it is the norm.
The supervisors claim that people don't pay attention unless there is an
instruction. Unfortunately, now that so many parts have instructions, people
have stopped paying attention to them at all.

What suggestions do you have for improving the attentiveness of the line
personnel to the proper way to build?
(You don't have to limit yourself to the spreadsheet column. Other forms of
learning can take place.)

thanks,
karen

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