Automotive Manufacturing Documentation
When to Activate This Skill
- "Write a work instruction for [process]"
- "Create a business process for [operation]"
- "Document manufacturing procedure"
- "Build SOP for [automotive process]"
- "Create APQP documentation"
- "Write quality inspection procedure"
- "Document assembly/machining/material handling process"
Core Document Types
1. Work Instructions (WI)
Purpose: Detailed step-by-step operator guidance Key Elements:
- Clear title and document ID
- Scope and applicability
- Required materials, tools, equipment
- Safety warnings and PPE requirements
- Numbered sequential steps with visual aids
- Quality checkpoints and acceptance criteria
- References to specifications/standards
2. Standard Operating Procedures (SOP)
Purpose: Standardized process methodology Key Elements:
- Purpose and scope
- Responsibilities and authorities
- Process flowchart
- Detailed procedure steps
- Forms and records
- Related documents
- Revision history
3. Business Process Documents
Purpose: High-level process definition and control Key Elements:
- Process ownership
- Inputs and outputs
- Key performance indicators (KPIs)
- Process flow diagram
- Interaction with other processes
- Risks and controls
- Continuous improvement tracking
Standards Compliance
IATF 16949 Requirements
- Process approach methodology
- Risk-based thinking
- Turtle diagrams for process definition
- FMEA linkage
- Control plan alignment
- Layered process audits consideration
ISO 9001 Structure
- Context of organization
- Leadership and planning
- Support and operation
- Performance evaluation
- Improvement focus
APQP/PPAP Integration
- Process flow diagrams
- PFMEA considerations
- Control plans
- Work instructions as PPAP deliverables
- Measurement system analysis references
Writing Framework
Document Structure Template
1. HEADER
- Document Title
- Document Number
- Revision/Date
- Approvals (Prepared/Reviewed/Approved)
2. PURPOSE & SCOPE
- Why this document exists
- What processes/operations it covers
- What it doesn't cover
3. RESPONSIBILITIES
- Who performs the work
- Who supervises
- Who approves/validates
4. SAFETY & PPE
- Hazards and risks
- Required personal protective equipment
- Emergency procedures
5. MATERIALS & EQUIPMENT
- Parts/components list
- Tools required
- Equipment specifications
- Gages and measuring devices
6. PROCEDURE/STEPS
- Sequential numbered steps
- Action-oriented language (verb-first)
- Visual aids (photos, diagrams)
- Quality checks embedded
7. QUALITY REQUIREMENTS
- Specifications and tolerances
- Inspection frequency
- Acceptance/rejection criteria
- Rework procedures
8. RECORDS & DOCUMENTATION
- What gets recorded
- Where records stored
- Retention requirements
9. REFERENCES
- Related documents
- Engineering drawings
- Specifications
- Standards
10. REVISION HISTORY
- Date, revision, changes madeProcess Type Guidelines
Assembly Operations
- Focus: Sequence, torque specs, orientation
- Include: Part numbers, installation direction, fastener specifications
- Visuals: Assembly diagrams, before/after photos, exploded views
- Checks: Fit, alignment, function tests
Machining Operations
- Focus: Setup, program, tooling, parameters
- Include: Machine settings, feed/speed, tool specifications, fixtures
- Visuals: Setup photos, tool paths, measurement points
- Checks: Dimensional verification, surface finish, first-piece inspection
Quality/Inspection
- Focus: What to inspect, how to measure, accept/reject criteria
- Include: Gage R&R references, sampling plans, measurement methods
- Visuals: Measurement locations, gage usage, defect examples
- Checks: Calibration verification, data recording
Material Handling
- Focus: Movement, storage, protection, traceability
- Include: Handling methods, storage conditions, labeling, FIFO
- Visuals: Packaging methods, storage layouts, label formats
- Checks: Condition verification, count accuracy, traceability
Best Practices
Writing Style
- Active voice: "Insert the bolt" not "The bolt is inserted"
- Present tense: "Check the torque" not "The torque should be checked"
- Imperative mood: Direct commands to operator
- Concise: One action per step
- Specific: Exact values, not ranges when possible
Visual Elements
- Photos of actual parts/processes (preferred)
- Diagrams for complex assemblies
- Flowcharts for decision points
- Callouts for critical features
- Color coding for emphasis (warnings in red/yellow)
Quality Integration
- Embed quality checks within process steps
- Reference control plans
- Link to FMEA high-priority items
- Include mistake-proofing (poka-yoke) features
- Document inspection frequency
Revision Control
- Clear document numbering system
- Revision history table
- Change bars for modified sections
- Effective date tracking
- Training requirements for changes
Common Mistakes to Avoid
- Assuming operator knowledge
- Missing safety information
- Vague quantities or specifications
- No visual aids for complex operations
- Incomplete tool/equipment lists
- Missing quality acceptance criteria
- No revision history
- Passive voice or unclear instructions
Quick Reference: Document Selection
| Need | Document Type | Complexity |
|---|---|---|
| Operator guidance | Work Instruction | Low-Medium |
| Department procedure | SOP | Medium |
| Process definition | Business Process | Medium-High |
| Quality procedure | Quality SOP | Medium |
| Inspection method | Inspection WI | Low-Medium |
Output Format
When creating documents, structure output as:
# [DOCUMENT TITLE]
**Document Number**: [AUTO-XXX-####]
**Revision**: [X] | **Date**: [YYYY-MM-DD]
**Prepared**: _____ | **Reviewed**: _____ | **Approved**: _____
## 1. Purpose & Scope
[Content]
## 2. Responsibilities
[Content]
[Continue with standard sections...]Supplementary Resources
For comprehensive methodologies and advanced topics: read ~/.claude/skills/AutomotiveManufacturing/CLAUDE.md
For document templates: ls ~/.claude/skills/AutomotiveManufacturing/templates/
Integration with Related Skills
A3CriticalThinking
When manufacturing issues arise, use A3 problem-solving methodology:
- Quality defects → Root cause analysis (5 Whys, Fishbone)
- Process failures → Structured countermeasure development
- Decision making → Apply priority hierarchy (Safety → Customer → Cost)
Load A3 skill: read ~/.claude/skills/A3CriticalThinking/SKILL.md
SupplyChain
For supplier-related documentation and requirements:
- Supplier quality requirements in work instructions
- PPAP documentation for purchased components
- Incoming inspection procedures
Load SupplyChain skill: read ~/.claude/skills/SupplyChain/SKILL.md
HoshinKanri
For strategic alignment of manufacturing objectives:
- Cascade targets to shop floor metrics
- Link work instructions to quality objectives
- Bowling chart for manufacturing KPIs
Load HoshinKanri skill: read ~/.claude/skills/HoshinKanri/SKILL.md
Key Principles
Priority Hierarchy (from A3CriticalThinking):
1. SAFETY FIRST → Never compromise for cost or delivery
2. CUSTOMER VALUE → Quality that meets/exceeds requirements
3. SHAREHOLDER VALUE → Optimize after 1 & 2 are secured- Safety First: Always lead with safety considerations - this is non-negotiable
- Clarity Over Brevity: Be clear, even if it takes more words
- Visual Communication: A picture is worth 1000 words
- Measurable Requirements: Specific, measurable acceptance criteria
- Traceability: Link to higher-level documents and standards
- Living Documents: Build in revision and improvement processes
- Problem Solving: Use A3 methodology for issues and improvements
Workflow Routing
| Request Type | Workflow | Output |
|---|---|---|
| "Write work instruction for [process]" | Work Instruction template | Numbered WI document with all 10 sections |
| "Create SOP for [department/process]" | SOP template | Standard procedure with flowchart |
| "APQP documentation" | APQP/PPAP integration | Phase-aligned docs: process flow, PFMEA linkage, control plan, WI |
| "IATF 16949 clause mapping" | Standards compliance | Turtle diagram + clause-by-clause alignment table |
| "Business process document" | Business Process template | High-level process with KPIs and risk table |
| "Inspection/quality procedure" | Quality SOP template | Inspection WI with gage specs and sampling plan |
| Complex quality issue | → A3CriticalThinking | Load A3 skill for root cause + countermeasure |
| Supplier requirements | → SupplyChain | Load SupplyChain skill for PPAP/SQE docs |
Examples
Example 1: APQP Work Instruction Draft
Input: "Draft a work instruction for the damper assembly final inspection station as an APQP deliverable."
Output structure:
WI-QUA-DAMP-001 | Rev A | APQP Phase 4 | PPAP Element 11
Purpose: 100% end-of-line inspection for DSS damper assemblies before shipment.
Safety: Safety glasses mandatory. WARNING: Damper contains pressurised gas — do not disassemble.
Steps:
1. Retrieve damper from assembly conveyor
2. Visual: inspect for scoring, leaks, damage — reject on any defect
3. Rod extension length: 245mm +/-1mm (gauge G-044) — record on TL-DAMP-001
4. Leak test: submerge 30s in water bath — zero bubbles (CRITICAL: PFMEA #7, RPN 160)
5. Scan serial number into MES for traceability
6. Place approved part in shipping rack DS-007IATF 16949 linkage: clause 8.5.1 (control of production), 8.6 (release), PPAP Element 11.
Example 2: IATF 16949 Clause Mapping for CNC Machining
Input: "Map our CNC turning operation to IATF 16949 — what do we need to document?"
| IATF 16949 Clause | Requirement | Required Document |
|---|---|---|
| 7.1.3 | Infrastructure | Equipment list, PM schedule |
| 7.1.5 | Measurement resources | Calibration register, MSA records |
| 7.2 | Competence | Operator skills matrix, training records |
| 8.1 | Operational planning | Process FMEA, control plan |
| 8.5.1 | Control of production | Work instruction WI-MCH-TURN-001, setup sheet |
| 8.5.2 | Identification & traceability | Part labels, traveller, lot records |
| 8.6 | Release of products | First-off/last-off inspection record |
| 9.1.1 | Monitoring & measurement | SPC charts on critical dims (Cpk >= 1.67) |
| 10.2 | Nonconformity & corrective action | NCR process, 8D for customer complaints |
Turtle Diagram (CNC Turning):
- Inputs: Raw bar stock (cert req'd), drawing rev B, CNC program P-4567
- Outputs: Turned component to drawing tolerances, first-off inspection record
- With What: CNC lathe, tooling per setup sheet, CMM for FAI
- How: Work instruction, SPC control plan
- Who: Level 2 machinist min; QE sign-off for new setups
- Metrics: Cpk >= 1.67 on critical dims, scrap <= 0.5%, OEE >= 80%