Manufacturing SOPs are used to ensure that workers follow the prescribed steps for processes and operations. SOP stands for Standard Operating Procedure, and in manufacturing, can be used by plant operations managers when performing walkthrough inspections to verify worker compliance and note non-compliance.
A manufacturing SOP (Standard Operating Procedure) is a set of documented step-by-step work instructions designed to guide workers in performing manufacturing tasks. Manufacturing SOPs helps promote work consistency, prevent loss of quality, and retain brand reputation.
A good manufacturing SOP is designed to streamline the production process while minimizing the risk of errors. Noncompliance with manufacturing SOPs could result in the following consequences:
Complying with regulations and producing consistent outputs don’t have to be an arduous journey. Preparing a well-written manufacturing SOP document can guide employees to perform routine tasks in the best and safest way possible. There is no official standard in writing an SOP document. However, some steps can help in writing an effective SOP.
Writing your manufacturing SOP begins with thinking of what you want to accomplish. Whether starting a new process or improving an existing one, determining the end game or the goal makes it easier to write the SOP document.
To give you an idea, we’ve written down the following examples:
The scope defines the extent of your SOP document. It clarifies details such as limitations or exceptions of the SOP, and the people who will be engaging with it or will be impacted.
Chemical Manufacturing Lab
– Who is the SOP for?
Lab Personnel and Tablet Press Operators
– Are there any specific limitations or exceptions to this SOP?
This only applies to the production of pharmaceutical tablets.
Chemical Manufacturing Lab
– Who is the SOP for?
Lab Personnel and Tablet Press Operators
– Are there any specific limitations or exceptions to this SOP?
This only applies to the production of pharmaceutical tablets.
There are various formats you can write an SOP document. A manufacturing SOP commonly uses a step-by-step format, which is straightforward and easy to follow. There’s also the hierarchical format which is similar to the prior, the only difference is that it provides more detailed and specific instruction for each step. Lastly, the flowchart format where processes are illustrated. This is most suitable for processes that require decision-making. You can choose to use one or combine them, so long as it’s appropriate and can be easily understood by your audience.
Depending on the format you chose, start writing down the procedures of your SOPs focus. A good principle to follow when writing is the 5 C’s: clear, concise, correct, courteous, and complete. Doing so will help eliminate the guesswork from the procedure and ensure that each step performed is consistent.
Step 2 – Activate vents before turning on industrial machines
Step 3 – Set oven to 200°C for initial roasting of coffee beans
Step 4 – Set coffee freezing hall to -50°C
Step 5 – Put on thermal clothing before entering coffee freezing hall
Step 6 – Set low pressure vacuum at 60°C
Step 7 – Check conformity to specs and for visual defects during assembly line production
Step 8 – Perform final inspections before products are packed in boxes
After writing your SOP document, review and test it with other team members before sending it to stakeholders for approval. Once it gets approved, it will then be implemented and shared across relevant employees. However, it doesn’t stop there. SOPs should be continuously reviewed and updated, preferably every 6-12 months or as necessary.
For reference, here’s a completed example of SOP in manufacturing using a template:
