Faster Shop-Floor Work Instructions in ThingWorx with Windchill Documents
By PSPTechHub ·
Summary
Before operators can build anything, an engineer has to write the steps for each job: what to do, which drawings to use and what to check. PSPTechHub improved a ThingWorx process plan editor so engineers can copy an existing operation instead of starting from scratch, attach the latest released drawings straight from Windchill, and only save changes when they press Save. When every step of a job is finished, the results are sent back to Windchill. All 22 test cases passed in unit testing.
The Problem: Every Work Instruction Took Too Long
Engineers wrote the step-by-step instructions for every job in a ThingWorx editor. It worked, but every new operation took longer than it should, and small mistakes slipped through.
Starting from scratch every time
Even when a new operation was almost the same as an old one, engineers had to retype the work center, description, checks and documents.
Drawings uploaded by hand
Documents were uploaded from a local computer, so there was no guarantee they were the latest released version in Windchill.
Changes saved by accident
Checks and descriptions were saved the moment a popup closed, even if the engineer meant to cancel.
Easy to delete the wrong file
Official Windchill documents and operator uploads looked the same and could both be deleted.
Hard-to-read descriptions
The old text box made long instructions and check descriptions difficult to format.
The Solution: Copy, Attach and Save With Confidence
PSPTechHub added the features engineers asked for directly into the editor they already used, and connected it to Windchill so the right documents are always one search away.
Copy an existing operation
Pick a work order and an operation, and everything — work center, description, checks and documents — is copied into a new one, ready to edit.
Copy sub-operations too
Sub-operations can be copied on their own, or come along automatically when their parent is copied.
New copies start as drafts
Every copied operation, and its sub-operations, starts in Building status so nothing goes live before it is checked.
No clashing step numbers
The step number is chosen once and checked so two operations can never share it.
Attach drawings from Windchill
Search Windchill by name or number and attach the released document or CAD drawing linked to the part.
Save only when you mean it
Descriptions, documents, work centers and checks are saved only when Save & View is pressed.
Protect official documents
Only operator uploads can be deleted, Windchill documents are clearly marked, and every delete asks for confirmation.
Better text editor
A rich text editor makes long instructions and check descriptions easy to write and read.
Results sent back to Windchill
When every operation in a job is finished, the job's data is sent to Windchill automatically.
How It Works: From Plan to Shop Floor
- 1
Open the process plan
The engineer opens the job's process plan in the ThingWorx editor.
- 2
Copy or create an operation
They copy a similar operation from any work order, or start a new one; it opens in a new tab as a draft.
- 3
Attach the right documents
They search Windchill and attach the released drawings for the part.
- 4
Edit and review
They adjust the description, checks and work center in the rich text editor.
- 5
Save & View
Pressing Save & View stores every change at once; closing without saving discards them.
- 6
Build and report back
Operators follow the instructions on the floor, and when all steps are done the data goes back to Windchill.
For IT Teams: How It Is Built
ThingWorx runs the editor and the shop-floor screens; Windchill stays the official source of documents and receives finished job data.
- Process plan editor and viewerEdit and view screens for plans, operations, checks and documents
- Copy and validation servicesCopy operations and sub-operations, check step numbers, set draft status
- Document servicesSearch, download and attach Windchill documents; manage operator uploads
- Windchill linkSupplies released documents and CAD drawings, and receives finished job data
- ThingWorx database and file storeHolds operations, checks and uploaded files
ThingWorx services built
| Service | Purpose |
|---|---|
| Operation copy | Copies an operation and its children into a new draft |
| Step number check | Makes sure no two operations share a step number |
| Windchill document search | Finds released documents and CAD drawings by name or number |
| Save & View | Saves descriptions, documents, work centers and checks together |
| Send to Windchill | Shares the job's data once every operation is complete |
Design decisions
- Built into the existing editor, so engineers have nothing new to learn
- Windchill stays the source of official documents; uploads are kept separate and clearly marked
- All edits are held until Save & View, so closing a page never leaves half-saved data
- Copies always start as drafts, so nothing reaches the shop floor unchecked
- A fault found during testing — deleted files not being removed from storage — was fixed before release
- 22 test cases covering Windchill search, document rules, copying and saving, all passed in unit testing
Outcomes
New operations in minutes
Engineers copy what already works instead of starting again.
Always the released drawing
Documents come straight from Windchill, not from someone's computer.
No accidental changes
Nothing is saved until the engineer presses Save & View.
Official documents protected
Windchill documents can't be deleted by mistake.
Drafts before release
Copied operations are checked before anyone builds from them.
Windchill kept up to date
Finished job data flows back automatically.
This solution fits if you need to…
- Copy an operation in a ThingWorx process plan instead of rebuilding it
- Attach released Windchill documents to shop-floor work instructions
- Stop accidental saves in a ThingWorx work instruction editor
- Send completed job data from ThingWorx back to Windchill
- Protect Windchill documents from being deleted on the shop floor
Frequently Asked Questions
Can you copy an operation in a ThingWorx process plan?
Yes. In this solution engineers pick a work order and operation, and its work center, description, checks and documents are copied into a new draft operation they can edit.
How do you attach Windchill documents to work instructions?
Engineers search Windchill by document name or number from inside the editor and attach the released document or CAD drawing linked to the part.
What stops a copied operation going live by mistake?
Every copied operation and its sub-operations start in Building status, so they must be reviewed before use.
Can operators delete official Windchill documents?
No. Only documents uploaded from a local computer can be deleted, and every delete asks for confirmation.
When are changes saved?
Only when Save & View is pressed. Closing the page without saving discards the changes.
Does the data go back to Windchill?
Yes. When every operation in a job is complete, the job's data is sent to Windchill automatically.
How was the solution tested?
22 test cases covering Windchill search, released and CAD documents, delete rules, copying, sub-operations and saving were all passed in unit testing.