What does an AI-generated work instruction contain?

A list of operations in the correct sequence, machines and tools required, setup parameters (speed, temperature, pressure), material consumption norms, quality checkpoints, and estimated operation times.

How accurate are the estimated operation times?

For products similar to those already in the system: accuracy ±10–15 %. For completely new product types: ±25–30 %, but still a faster starting point than writing from scratch.

Does it integrate with ERP systems for bills of materials (BOM)?

Yes — the routing is automatically linked to the BOM in Modulario. A change in the BOM is reflected in the routing and vice versa.

AI auto-generation of work instructions: manufacturing documentation without the grind

A manufacturing process plan (routing / work instructions) is the foundation of production documentation. Every new product needs one. For a company introducing 50+ products per year, creating routings from scratch is an enormous burden on the engineering team.

What a routing defines and why it takes so long

A routing defines:

Sequence of manufacturing operations
Which machine performs each operation
Setup parameters (RPM, feed rate, temperature, cycle time)
Tool and material consumption norms
Quality checkpoints and measurement methods
Labour time norms (for cost calculation)

An experienced process engineer needs 4–8 hours to write a routing for a new product. Adding 5–10 products per month means 20–80 hours of pure documentation work.

How AI generates the routing

Analysis of similar products

For a new product, AI identifies the 3–5 most similar products in the history (same material group, similar dimensions, similar processing method).

Parameter extrapolation

AI adjusts parameters from similar routings based on the new product’s specs:

Larger diameter → different RPM, longer operation time
Different material → different cutting parameters, different processing temperature

Routing structure generation

MANUFACTURING PROCESS PLAN
Product: Shaft HŠ-2245 | Rev. 00 | 2026-05-03

Op. 10: Rough turning
  Machine: CNC Mazak QT-250
  Tool: DNMG 150608-MF (T01)
  RPM: 1,200 | Feed: 0.25 mm/rev | Depth: 2.0 mm
  Standard time: 8.5 min/pc

Op. 20: Finish turning
  ...

Op. 30: Dimensional inspection (100 % control)
  Measuring instrument: Micrometer 50–75 mm
  Tolerance: Ø60 h6 (-0.019/-0.011)

Engineer review and approval

The generated routing is sent to the process engineer for review. They check critical parameters and either approve or adjust.

Review and approval time: 30–60 minutes (vs. 4–8 hours writing from scratch).

Integration with the production system

After approval the routing is immediately available:

On the CNC machine (printed sheet or digital terminal)
In the production planning system (operation times for capacity planning)
In cost calculation (norms for labour and material costing)

AI auto-generation of work instructions — manufacturing process docs in minutes