Preparing a Work Instruction for an ESOP System

An electronic standard operating procedure (ESOP) should help an operator identify the correct task, follow the approved method and recognize when to stop and ask for support. Preparing the instruction carefully is as important as displaying it on a workstation terminal.

Start by defining where the instruction applies. Identify the product or product family, operation, workstation and process revision. If different product variants require different methods, describe the selection conditions clearly rather than combining conflicting steps in one instruction.

Write the work sequence in the order in which the operator performs it. Use direct action verbs and give each step a clear purpose. Include the tools, materials and preparation required before the task begins. Use photographs or diagrams when they make orientation, assembly position or an inspection point easier to understand.

Keep process requirements tied to their approved source. Dimensions, tolerances, tightening requirements, inspection limits and equipment settings should come from the applicable drawing, process specification or controlled quality document. Do not add a numerical requirement because it appears in another product's instruction. Where a value depends on the product variant, identify the relevant variant and reference explicitly.

Separate routine work from abnormal conditions. Explain what the operator should check, what a satisfactory result looks like and what action is required when the result is outside the approved criteria. Escalation instructions should identify the responsible role and follow the site's existing quality and safety procedures.

Before release, have the responsible process and quality personnel review the instruction. Check the revision identifier, effective date and approval status. Confirm that the displayed text and images remain readable on the actual workstation screen and that the instruction can be selected for the intended operation.

During a controlled trial, ask an appropriately trained operator to follow the instruction at the workstation. Record unclear wording, missing preparation and steps that do not match the approved process. Revise and approve the document before wider use.

After release, manage changes through the established document-control process. Replace superseded revisions, retain the required revision history and review affected instructions when the product, tooling, equipment or process changes. The ESOP display should present the approved instruction for the current task, while the underlying process owner remains responsible for its technical accuracy.