Template

Digital Work Instruction Template & 3‑Minute Microlearning Episode

A modular, platform‑agnostic digital work instruction template with detailed blocks, examples, and a ready-to-use 3‑minute microlearning script for coaches. Use this to create short, visual, step‑by‑step instructions that reduce variation, speed onboarding, and keep knowledge current as living content.

Purpose

This template helps teams create short, visual, step‑by‑step digital work instructions (DWIs) and a linked 3‑minute microlearning episode for on‑the‑job coaching. It is platform‑agnostic: copy fields into your LMS, digital job aid, tablet UI, or PDF and keep content light, visual, and testable on the floor.

How to use this template

Fill each block with concise, observable, and testable information. Prefer photos or short video clips over long text. Validate the instruction with an operator and coach on the shop floor before publishing. Assign an owner and a review cadence so the content remains living knowledge.

Template Blocks (with guidance)

  1. Title

    Clear, searchable name. Example: "Press Die Change — Model X100 (2‑person)"

  2. Objective

    One short sentence describing the intended outcome and quality standard. Example: "Change the X100 die and verify setup so parts meet dimensional spec ±0.25mm and scrap rate <1% within first run of 25 parts."

  3. Scope & Applicability

    Where and when to use this instruction (machines, shifts, skill levels). Example: "For Line 2 presses during scheduled die changes; requires trained operator + coach for first three uses."

  4. Estimated Time

    Typical time range and a target. Example: "Target 18–25 min (average 20 min)."

  5. Required tools, parts & consumables

    List items and minimum spares. Add tool photos or SKU numbers. Example: "Torque wrench (0–50 Nm), lifting clamp #A12, shim kit S‑5, cleaning cloth, Lockout hasp #M45."

  6. Safety checks & PPE

    Specific safety steps that must occur before starting. Keep this short and actionable. Example: "Isolations completed & tagged (LOTO), verify zero energy, eye protection, steel toe, two‑person lift for die >25 kg."

  7. Prerequisite skills or approvals

    Any permits, qualifications, or authorizations needed. Example: "Operator must be signed off on Die‑Change Level 1; supervisor approval required for first run if adjusted beyond shim limits."

  8. Step‑by‑step procedure

    Numbered steps with one action per step, each paired with an image or short video clip. Use consistent verbs (Check, Remove, Install, Torque, Verify). Call out critical parameters and tolerances. Example format for a step:

    Step 4 — Install lower die (photo/video slot)

    • Action: Position lower die on locating pins.
    • Critical: Confirm index notch aligns to mark; torque plate bolts to 35 Nm.
    • Time: ~3 min
  9. Expected outputs & acceptance criteria

    What a successful result looks like and how it's measured. Example: "First 25 parts measured: all within dimensional spec; no burrs; scrap <1%."

  10. Common mistakes & quick fixes

    Short list of frequent errors, their symptoms, and immediate fixes. Example: "Misaligned lower die — symptom: part offset left 0.5mm. Quick fix: re-seat on locating pin, re‑torque bolts, recheck sample."

  11. Verification & sign‑off steps

    How to verify the job is done and who signs. Include measurement checks and sample size. Example: "Measure 5 parts at locations A & B using calipers. Supervisor initials digital checklist after verification."

  12. Troubleshooting & escalation

    When to stop and escalate, and to whom. Example: "If dimension out of spec after two adjustments, stop and call maintenance. Log condition in defect board."

  13. Reference materials & change history

    Links to drawings, SOPs, drawings number, and recent changes (owner, date, summary).

  14. Local adaptation notes

    Space for site‑specific adjustments, validated on the floor. Example: "Plant B uses clamp adapter A2 — operator note added 2025‑03‑12."

Visual guidance for images & video

  • Use clear, well‑lit photos: close‑ups for critical points, wide shots for setup orientation.
  • Prefer short clips (5–20s) showing the exact hand movements or torque action.
  • Annotate images with arrows, step numbers, and brief captions (keep captions <12 words).
  • Include a single image that highlights the single most important error to avoid for each critical step.

3‑Minute Microlearning Episode (Coach‑led)

Use this script for a short on‑the‑job coaching moment, toolbox talk, or quick refresher video. Keep it interactive: ask the learner to show or try the critical step immediately after demonstration.

0:00–0:20 — Hook & Objective

Coach: "This 3‑minute refresh shows the one thing that avoids the most scrap during a die change — correctly seating the lower die. Goal: perform the die change and pass the 5‑part check within 25 minutes."

0:20–0:50 — Show tools & safety

Coach holds the torque wrench and locating pins: "We need these tools, LOTO in place, two people for heavy lifting, eye protection. Confirm LOTO and weight plan before you start."

0:50–1:50 — Demonstration of the critical step

Coach demonstrates seating the lower die and torquing bolts. Narration: "Seat die on these two locating pins so the notch faces the mark. Hand‑tighten, then torque to 35 Nm in an X pattern. If you skip the X pattern the plate can tilt — see how that creates offset?" (show close‑up).

1:50–2:20 — Quick verification

Coach: "Now run 5 parts and measure at A and B. If all within spec, sign the checklist. If not, re‑check seating and torque. If still not OK after two tries, stop and escalate to maintenance."

2:20–2:50 — Common mistake & quick fix

Coach shows an example: "Common mistake: over‑torque on one side — parts shift left. Quick fix: loosen, re‑seat, torque to spec in pattern. If shim stack is > allowed, stop."

2:50–3:00 — Call to action

Coach: "Try the seating now with me — two minutes each. When you finish, mark the digital checklist so we can track training. If you find a step that's unclear, note it in the 'Local adaptation notes' and we'll update the DWI."

Validation & change control

  • Validate on floor: pilot with two operators across shifts before full rollout.
  • Owner: assign a single content owner and one backup.
  • Review cadence: schedule a quick review every 6 months or after any related defect/incident.
  • Versioning: include version number and last‑review date in header.

Local adaptation checklist (before publishing)

  1. Does each step have a photo or short clip? (Yes/No)
  2. Are critical parameters called out (torque, tolerances, sample sizes)? (Yes/No)
  3. Has an operator validated this procedure on the floor? (Name & date)
  4. Is owner assigned and review cadence set? (Name & date)
  5. Is the microlearning script attached to the DWI for coach use? (Yes/No)

Example snippet (for a step)

Step 6 — Apply torque to plate bolts

  • Action: Tighten bolts in X sequence to 35 Nm.
  • Image slot: photo showing torque wrench on bolt X
  • Why: Uneven torque causes die tilt and off‑center parts.
  • Verification: Measure sample part feature C; tolerance ±0.25mm.

Notes on platform use and distribution

This template is intentionally neutral. When copying into a specific platform, consider adding:

  • Interactive checklist to capture who performed/verified the step and time stamps.
  • Short feedback field so operators can suggest improvements (stores change suggestions for owner review).
  • Links to training records so coaches can check prior sign‑offs before assigning practice tasks.

Change log (example)

v1.0 — 2025‑03‑01 — Initial draft. Owner: Maintenance Tech Lead
v1.1 — 2025‑04‑12 — Added torque values and microlearning script. Owner: Process Engineer

Quick template export checklist

When exporting for use on tablets or training systems, include:

  • Title, Objective, Estimated Time, Owner
  • Step images/videos embedded or as referenced assets
  • Interactive verification items (pass/fail, initials, sample measurement fields)
  • Link to full SOP and change history
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