| name | Automotivemanufacturing |
| description | Expert guidance for writing automotive manufacturing business processes, work instructions, and standard operating procedures. Follows IATF 16949, ISO 9001, and APQP/PPAP standards. Covers assembly, machining, quality/inspection, and material handling. USE WHEN user says 'write work instruction', 'create business process', 'automotive SOP', 'manufacturing procedure', 'APQP documentation', 'process flow', or 'quality procedure'. Integrates with A3CriticalThinking for problem solving and SupplyChain for supplier requirements. |
| effort | medium |
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 made
Process 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-007
IATF 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%
