INTRODUCTION Lean Manufacturing Visual Factory is a term to describe how data and information is conveyed in a lean manufacturing environment. In a lean manufacturing environment time and resources dedicated to conveying information are considered as a form of waste , even though it’s essential. Use of visual methods such as signs, charts and andons, enable easy access to the information & the current status of all processes will be immediately apparent. The more complex the process the more critical the exchange of information is to the process. Lean Manufacturing Visual Factory is a set of tools that allow for accurate and efficient information conveyance. Visual Factory is implemented in two stages – determining what information needs to be communicated and how this is accomplished. Starting point of lean manufacturing visual factory is the identification on information, what needs to be conveyed. The information required to get from one state to another is to be conveyed and the current state must be compared to the future state goals in order to determine what information is to be delivered. How the information is conveyed depends on the expected end result. The location and method of information delivery also depends on the relevancy of the information. Typically this data includes; Process metrics- Process metrics are typically displayed at the machine or cell; therefore it is most effective as it is delivered in real time. Immediate feedback facilitates immediate improvement. E.g.: If light is used to indicate information it is referred to as an andon. Andons are often the centerpiece of the lean manufacturing visual factory because it conveys tremendous real-time process information. Work instructions- Highly visual instructions with photographs and graphics will generally minimize production errors. The more information can be conveyed visually the more it will improve communication. Therefore work instructions are typically posted in the production areas. General plant information- Lean manufacturing relies on bi-directional information exchange throughout the organization. In a visual factory environment information is delivered to inform, alert and motivate. Therefore general plant information is typically posted in a central location where everyone has access to it. Lean Manufacturing Visual Factory Allows Companies to communicate and provide world class performance. Thus the efficient timely communication allows organizations to function at their full potential with added benefits such as; Reduce Errors Increase Employee Moral Increase Machine Uptime Increase Machine Run Rates Decrease WIP (Work in Progress)
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INTRODUCTION Lean Manufacturing Visual Factory is a term to describe how data and information is conveyed in a lean manufacturing environment. In a lean manufacturing environment time and resources dedicated to conveying information are considered as a form of waste, even though its essential. Use of visual methods such as signs, charts and andons, enable easy access to the information & the current status of all processes will be immediately apparent.The more complex the process the more critical the exchange of information is to the process. Lean Manufacturing Visual Factory is a set of tools that allow for accurate and efficient information conveyance. Visual Factory is implemented in two stages determining what information needs to be communicated and how this is accomplished.Starting point of lean manufacturing visual factory is the identification on information, what needs to be conveyed. The information required to get from one state to another is to be conveyed and the current state must be compared to the future state goals in order to determine what information is to be delivered. How the information is conveyed depends on the expected end result. The location and method of information delivery also depends on the relevancy of the information. Typically this data includes; Process metrics- Process metrics are typically displayed at the machine or cell; therefore it is most effective as it is delivered in real time. Immediate feedback facilitates immediate improvement. E.g.: If light is used to indicate information it is referred to as an andon. Andons are often the centerpiece of the lean manufacturing visual factory because it conveys tremendous real-time process information. Work instructions- Highly visual instructions with photographs and graphics will generally minimize production errors. The more information can be conveyed visually the more it will improve communication. Therefore work instructions are typically posted in the production areas. General plant information- Lean manufacturing relies on bi-directional information exchange throughout the organization. In a visual factory environment information is delivered to inform, alert and motivate. Therefore general plant information is typically posted in a central location where everyone has access to it.Lean Manufacturing Visual Factory Allows Companies to communicate and provide world class performance. Thus the efficient timely communication allows organizations to function at their full potential with added benefits such as; Reduce Errors Increase Employee Moral Increase Machine Uptime Increase Machine Run Rates Decrease WIP (Work in Progress)
Visual ManagementIn the organizational world Visual Management is a management system that attempts to improve organizational performance through connecting and aligning organizational vision, core values, goals and culture with other management systems, work processes, workplace elements, and stakeholders, by means of stimuli, which directly address one or more of the five human senses (sight, hearing, feeling, smell and taste). These stimuli communicate quality information (necessary, relevant, correct, immediate, easy-to-understand and stimulating), which helps people make sense of the organizational context at a glance by merely looking around. It is a management approach that utilizes either one or more of information giving, signaling, limiting or guaranteeing (mistake-proofing/ poka-yoke) visual devices to communicate with doers, so that places become self-explanatory, self-ordering, self-regulating and self-improving. Selected place: Training Centre at a Garment FactoryVisual tools changes the training Centre to more visualized environment so that even a new employee can be adjusted to working conditions use of visual controls. Itll give a positive picture on the factory.Training room layoutThe placement of the machineries can be marked using floor marks to guide the employees to place them in an arranged layout. Also the different colour tapes can be used to mark necessary placements of hazardous, scrap, working machineries, materials, etc. so that easy identification is possible. Trainers & Supervisors lobby
Store units Machines
Display unitSpecial Machines
Machine bed arrangementMachine bed can be arranged according to the machine type & the type of the operation. Few sample machineries can be visually displayed as a poster or notice, so that everyone gets to know the arrangement of common operations. This can be visually displayed using display boards at the training Centre with procedures so that user can easily identify simple instructions of the procedure.
Visual OrdersLocation identifiers for tools, parts, materials, product, equipment, etc can be used to create more organized, clean & tidy environment. Pathways can be drawn, indication of each tool placement places, first aid box , materials, folders, etc ease the work by ease of identification of lost tools, reduce time for finding tools, etc. Even for a new trainee it will be easy to find any tools they need. Shadow boards can be used to place all necessary tools required. Few examples were illustrated below.
Visual Standards & Visual aidsDisplay procedures and technical information at the point of use to ensure that best practices are followed consistently by all employees. Quality procedures, GSD codes can be placed at the each machine to aid the trainees to get used to standards. Needle break down procedure, Procedure of the sewing operation, quality spec, etc can be used to aid them visually. Also for the basic trainees the procedure of threading the machine, bobbin adjustment, etc. can be trained easily using visual standards. Continuous access to these standards guides them to follow the standards.
Threading the machine
Threading bobbin winder
Visual equipmentOperator control labels, gauge indicators, inspection and service labels, hazard warning labels can be used to facilitate training on autonomous maintenance.
Visual Matrics /DisplaysScore boards, banners, learning curve displays, performance matrics, skill matrics for each trainee can be displayed in each machine. It will help to each trainees improvements easily. A simple colour code can be used to place on top of the machine to indicate best performers, average performers, and weak performers.
Visual SafetyProper equipment hazard labels, chemical labels, warning signs, accident prevention tags can be used for necessary equipments, materials such as fusing machines, bonding machines, irons, etc.
Visual displaysDisplays of company policy, workers safety rules, quality guidelines, etc. will control the people visually by displaying the rules in wording or with the aid of signs. It enables the training on company culture & working environment, etc. Information display/board also can be used to display all necessary notices.
REFRERENCES
www.ptj.com. Importance and need of ergonomics in the apparel industry by K.Saravanan (Pakistan Textile Journal(2010) Liff, S & Posey, P A (2004), Seeing is Believing: How the New Art of Visual Management Can Boost Performance Throughout Your Organization, AMACOM, New York. Greif, M (1991), The Visual Factory: Building Participation through Shared Information, Productivity Press, Portland. Galsworth, G D (2005), Visual Workplace: Visual Thinking, Visual-Lean Enterprise Press, Portland.
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