Sequence Industries Semiconductor-High Tech

Work Instruction Software for High Tech Manufacturing

Semiconductor & Electronics Manufacturing

Manufacturers of high-tech hardware and instrumentation perhaps struggle more with constrained capacity and training issues than any other industry. Quite often, company growth or a new product launch is limited by the rate at which new manufacturing personnel can be hired and become effective. Add the complexity of highly configurable products to be more competitive and suddenly, role-specific work instructions are needed to effectively and profitably produce products.

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Manufacturers confirm that Sequence helps them to:

  • Reduce the time it takes for new hires to become effective;
  • Accelerate new product launch;
  • Adapt more quickly to changing product configurations and customer needs;
  • Generate correct manufacturing work instructions for highly configured products; and
  • Free up engineering time that was being spent helping to get product out the door.

Specific features of interest are:

General Capabilities

Deploying work instructions electronically allows real-time updates to the shop floor when they are approved facilitating rapid process improvement and change control.
Operators have access to only the most recently published version of an instruction... guaranteed! This prevents costly shop floor errors. The moment a work instruction is approved, it is immediately available for access.
Sequence allows you to include links to files on your network for viewing in their native formats; for example, CAD files, material certifications, etc.
Operators can be defined as expert or novice based on their skill level and experience.  Sequence automatically configures the level of detail presented to an operator.
Instead of leaving their station to fill out a paper form, operators can click a "Submit Request" button to provide instant feedback.  New to V3.1 is the ability to include both text and images.  Utilizing the built in camera on select tablet devices (iPad2, Samsung Galaxy Tab), images can be captured real-time during the submission process.  An email is automatically sent to manufacturing engineers containing the request, operator's name, product, specific work instruction step, along with a date time stamp. The affected instructions is flagged up to the subassembly level for ease of access.  Our customers indicate they are now learning more about "unspoken" issues in production.
When an operator attempts to access an instruction after a change, Sequence requires the operator to acknowledge the change before proceeding. Sequence maintains a log of all acknowledgements for all operators.

Additional WebSequence Enterprise Capabilities When Sequence is Integrated with your MRP / ERP System

Operators can view instructions by work order, as well as collect data (see the data collection feature below), eliminating guesswork associated with who worked on a work order, which instruction was used, and any data collected.
For customers that deploy instructions by work order and need to maintain records from operators, Sequence allows the capture of information.  This can include electronic signatures by operator/supervisor or production data like serial numbers, oven temperatures, etc. Tolerances can be set for numeric inputs and used as either a trigger for information to be validated and reentered or to generate a nonconformance.  Data can then be used to provide an as-built record of production for specific products. See "Access Instructions by Work Order" for more detail.
When instructions are accessed via work order, WebSequence allows authorized personnel to issue a Redline change against that work order.  This Redline is immediately propagated through all work orders for the affected assembly and is presetned to shop floor personnel as a pop-up notification when the affected instruction is reached.  The Redline remains in effect until the note is handled and the subassembly is republished.
When instructions are accessed via work order, WebSequence allows authorized personnel to approve a one time Proceed with Noncompliance for a unique work order.  The Proceed with Noncompliance information becomes part of the permanent manufacturing history for the affected work order.
When products have multiple options, Sequence will automatically display to an operator the configuration-specific instructions for a given work order. This eliminates operator confusion by only showing the necessary instructions to execute a work order.  In addition, this automates the traceability associated with the variety of ways a configured product can be built.
When instructions are accessed via work order, Sequence Enterprise allows modifications to be made to the affected work order without the loss of any previously captured data.  For example, should a part need to be reworked, the rework work instructions could be added to the work order detailing the complete manufacturing history while at the same time maintaining all previously captured signatures, data, etc. 

Embracing Innovation and Enabling Technology

High tech manufacturers face tough challenges. Theirs is a difficult business. Products can have thousands of parts, require hundreds of complex, manual steps to assemble, and change on a daily basis. It is no wonder that this industry, perhaps more than any other, struggles with issues of workforce training, standardization and business growth. How do you have that record quarter of sales when you can’t hire and train manufacturing personnel fast enough to get the product built CORRECTLY and out the door? While the problems are numerous, one key to high-tech manufacturing success is to capitalize on and embrace the enabling capabilities of new technology!

While not the cure for all growth problems, the ability to quickly capture tribal knowledge and convert that knowledge into effective work instructions has shown to be an invaluable enabler in high-tech manufacturing companies. Sequence is an efficient, cost-effective tool to transform “tribal knowledge” into “corporate knowledge” that adds significant value to your company’s bottom line.