Work Instruction and Job Aid Template
Four documents and four sheets that cut a procedure down to the page somebody works from, then track every copy of it in the building.
Free download · No account needed
Work Instruction
WI-014 Filler bowl changeover
| Station | Line 2 inline filler, 24-head |
| Revision | 2.1 |
| Derived from | OPS-06 Rev 4 |
| Issued | 2 April 2026 |
| Verified | 2 April 2026, J. Okoro (shift lead) |
Before you start
Line stopped, CIP not running, changeover kit at the station, gasket in hand. If any of the four is missing, stop here.
| # | Do this | Figure |
|---|---|---|
| 3 | Lock out the filler drive at the MCC breaker and keep the key on you | breaker F2-14 |
| 4 | Open the bowl drain valve and let it run until the flow stops | |
| 5 | Confirm the bowl pressure gauge reads zero before touching the guard | 0 bar |
| 10 | Hand-start all four bolts before tightening any | |
| 11 | Tighten in a diagonal cross pattern, in two passes | 12 Nm |
The line that makes a card falsifiable
Derived from OPS-06 Rev 4. The day OPS-06 reaches Rev 5, the operator standing here can see that this page predates it, without checking a register, without asking anyone, and without the card having to be wrong.
Stop and call the shift lead if
The gauge reads above zero after the drain. The seat face is scored. The interlock light stays red with the bolts tight.
Somebody is standing at a machine with one hand free. Whatever is in the other hand is the document your company actually operates on, and it is almost never the procedure filed in the quality system. It is a laminated card taped to a guard rail, and nobody in the building can tell you what revision is printed on it. The formatting question was settled years ago. Whether that card still matches the procedure in force never was.
So the control block carries a field no template in this genre has: the parent procedure and its revision number at the moment the page was cut. `Derived from OPS-06` is unfalsifiable. `Derived from OPS-06 Rev 3` becomes wrong the day OPS-06 reaches Rev 4, visibly, on the card, where the operator sees it without checking a register. Orphaned clears as unaffected, reworded or changed, and changed obliges retraining whenever the energy control procedure moves. A card describing a task nothing governs is not a filing gap, it is a procedure worth writing.
Then the copies. Every laminated card, binder page and unissued photocopy in the maintenance crib gets a row carrying the revision printed on that copy, which turns replacing the cards into a countable list. Under drug production rules the procedure has to be documented at the time of performance, so the record column belongs on the page. Send River the procedure and photographs of what is hanging up, or take the documents and CSV sheets blank, next to the audit that ranks undocumented processes and the rest of the template library.
What's in the pack
Instruction Register
One row per instruction, keyed on the station rather than the task. It carries the parent procedure, the parent revision the page was cut from, and the parent revision in force now, so an orphan is a comparison rather than somebody's recollection.
Point of Use Log
One row per physical copy: the laminated card at the guard rail, the binder page, the sheet taped inside a cabinet door, the photocopy nobody issued. Each row holds the revision printed on that copy, which is what turns replacing the cards into a finishable job.
Version Control
One row per revision event with the trigger, the retraining verdict, the count of copies to pull and the approver. An orphan nobody has re-derived gets a row with no approver and the state open, because an open row is the only thing that stops it going quiet.
Verification Record
The four facts a real compliance certification names, plus the column that decides whether the row means anything: whether the person performing it was independent of the people who use the instruction.
Work Instruction Format
The house shape for a single page: the six-field control block, the figures in their own right-hand column, the accept criterion beside its step, and the four things this format deliberately leaves out. The one-page test is a real test and the cut order is written down.
What a Parent Revision Obliges
The cascade. Every derived instruction is orphaned the moment its procedure moves, and clears as unaffected, reworded or changed. It also lists the six changes that are always changed, whatever the parent's own change note calls them.
One-page Job Aid
A filled instruction, fifteen steps for a filler bowl changeover, so the format is arguable against something real instead of against a bracketed placeholder. Every design choice on the page is annotated underneath it.
Quick Reference Card
Seven lines, sized for a laminated 4x6, plus the three conditions a task has to pass to earn one. A task failing the training condition needs the walkthrough written up properly rather than a card that assumes competence.
How to use it
- 1
Open in River, or take it blank
Open the pack in River and hand it the procedure, or download the documents and CSV sheets and fill them in yourself.
- 2
Send the procedure and the photographs
The parent procedure, plus photographs of the cards already hanging at the stations. Those photographs settle which revision each station is running, and nobody expects to be asked for them.
- 3
Count the stations, then cut
A procedure that reads as one task is usually two or three instructions: a hand-fill bench and an inline machine are different pages. Each comes out at one side, figures in a column.
- 4
Log the copies and verify at the machine
Every copy gets a row with the revision printed on it. Then somebody who does not use the instruction watches it being used and reads the figure column against the machine plate.
Frequently asked questions
Is this free, and what do I actually download?
Free, no account and no card. The zip holds four Word documents and four CSV sheets. Edit with AI is the optional half: River reads your procedure, counts the stations it covers, and cuts a page for each. Other packs sit in the template library.
How is a work instruction different from the SOP it comes from?
Different reader and a different clock. A procedure is written to be governed, approved and reviewed. An instruction is written to be used at a station by somebody already trained, and it changes far more often, so it is versioned on its own.
What happens when the parent procedure gets revised?
Every instruction derived from it is marked orphaned before anything is assessed, then each one clears as unaffected, reworded or changed. Changed means the copies come down before the new ones go up and the retraining names go in the record first.
We have laminated cards everywhere and nobody knows which are current.
Photograph them. That is the input this pack wants most, because the revision printed on a card is the only reliable evidence of what a station is running. Each one becomes a row, and the ones carrying no revision at all get their own state.
Does this cover lockout and other safety procedures?
Yes, and the format bends to fit them. The hazardous energy standard asks specifically for the shutdown steps, the placement and transfer of the devices with who is responsible, and the requirements for testing that the isolation held. That last one is the step cards drop first.
Who is supposed to verify an instruction?
Somebody who does not work that station. The periodic inspection of an energy control procedure has to be performed by an authorised employee other than the ones using it, and a card its own operator signed off establishes nothing at all.
What does Edit with AI do here?
It signs you up, installs this pack as a private workspace, and puts River in front of the empty register. Then you send a procedure and whatever is hanging at the stations, including a photograph of a card by a machine, and it starts counting stations.
Put the right revision at the machine
Take the documents and CSV sheets blank, or open this exact pack in River and send it the procedure plus a photograph of what is taped up now.
Edit with AI