Routing & instructions

✅ Why this step turns knowledge into repeatable process

Even a perfect design can fail—if no one knows how to build it correctly.

Routing and instructions define the exact sequence, method, and tools used to assemble, test, and package your product. This step ensures every build follows the same path—whether it’s the fifth prototype or the 5,000th unit. It reduces mistakes, training time, and rework.

📘 What you’ll document

  • The sequence of steps required to produce each unit
  • Key operations, tools, durations, and required inputs
  • Assembly stations, routing paths, or batch flow
  • Clear, visual instructions that anyone on the line can follow
  • Integration with ERP or PLM systems if scaling production

🛠️ Tools and methods

  • Routing Sheets or Cards

    Step-by-step operations with station number, description, and estimated time.

  • Work Instruction Documents (WIs)

    Visual and written instructions showing what to do at each step.

  • Station Flow Diagrams

    Map how product moves through tools, benches, or stations.

  • QR Code / Batch Tracking

    Link routing steps to digital checklists or inventory systems.

  • Skill & Tool Requirements per Step

    Identify if a specialist or calibrated equipment is required.

⚠️ Pitfalls to avoid

  • Skipping detail. “Assemble housing” is not a useful instruction—show each screw, direction, and tool.
  • Overloading one step. Too many actions in one routing item leads to errors.
  • No visual support. Words alone aren’t enough—add photos, arrows, or drawings.
  • Ignoring updates. Always revise instructions when the product or process changes.

💡 From the assembly line

“We added arrows and tool icons to the work instructions—and error rates dropped by 30%. It wasn’t the build that was wrong. It was the way we explained it.”

– Process Engineer, Smart Systems SME

💡 Watch someone follow your instructions for the first time. Wherever they pause, struggle, or guess—improve that step.

🔗 Helpful links & resources

✍️ Quick self-check

  • Do we have a clear step-by-step guide for how the product is built?
  • Are all tools, inputs, checks, and durations listed?
  • Can someone unfamiliar with the product follow the instructions and succeed?
  • Are routing steps reviewed and updated alongside design or tooling changes?

🎨 Visual concept (optional)

Illustration: A workstation with a routing card showing Step 4: “Install battery – 2Nm torque – Tool: TX6”. An overhead screen displays a visual guide with arrows and tool icons. A printed checklist is clipped to the fixture, marked “Step 4 – Done”.

Visual shows how routing and instructions create repeatable, high-quality production by guiding every action—clearly and consistently.
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