Visual Factory

MASS LEAN CULTURE

MASS LEAN CULTURE

Objectives:Upon completion of this module, you will be able to:

� Describe 5 S’s

� Discuss and give examples of Visual Displays and Controls

� Give examples of how you can use Visual Factory techniques as a Manufacturing Engineer

MASS LEAN CULTURE

Visual Factory is the use of controls that will enable an individual to immediately recognize the standard and any deviation from it.

Visual Factory

MASS LEAN CULTURECharacteristics Of Visual Factory

� There is nothing extra

� The environment is immaculate, safe, and self-cleaning

� Standards are easy to recognize and abnormal conditions are easy to correct

� Performance and progress are readily apparent

� Zero Defects is a reality!

MASS LEAN CULTUREElements Of The Visual Factory

Workplace Workplace

Organization and Organization and

StandardizationStandardization

Share Share

InformationInformation

Prevent Prevent

Defects Defects

and Errorsand Errors

Visual Visual Display

Display

Visual Visual Control

Control

5 S5 S

MASS LEAN CULTURE

� Name a large company that has an excellent reputation for quality and customer satisfaction.

What would you expect to:What would you expect to:•• seesee•• hearhear•• smellsmell•• feelfeel•• tastetaste

if you visited this business?if you visited this business?

Brainstorm

MASS LEAN CULTURESort (Organization)

Distinguish Between What Is And Is Not Needed

MASS LEAN CULTURESort - Red Tagging

� A visible way to identify items that are not needed or are in the wrong place in the workplace

� Obsolete, unneeded?� Stored here, used elsewhere?� Used infrequently?� What the heck is THIS used for?

MASS LEAN CULTUREApply Visual Factory...

MASS LEAN CULTURE

• • Temporary storageTemporary storage

• Local holding area• Local holding area

• Central holding area• Central holding area

• Holding area manager• Holding area manager

• Timely clearing• Timely clearing

Sort - Red Tag Holding Areas

MASS LEAN CULTURE

"A Place For Everything and Everything In Its Place"

Stabilize (Orderliness)

MASS LEAN CULTUREShine (Cleanliness)

� Eliminating all forms of contamination

� Finding ways to keep the workplace clean

� Adopting cleaning as a form of inspection

� Making cleaning part of everyday work

MASS LEAN CULTURE

Maintain and monitor the first three Keys

Standardize (Create Rules)• Check• Check• Standardize• Standardize• Maintain• Maintain• Monitor• Monitor• Improve• Improve

MASS LEAN CULTURESustain (Self-Discipline)

� Correct procedures are a part of the Manufacturing process.

� Workers are properly trained

� Everyone has adopted Visual Factory

� The workplace is well ordered according to agreed upon procedures

� Managers, operators, and Engineers are deeply committed to the 5 Keys

MASS LEAN CULTURE

How to Use Visual Displays And Controls

� Overview of Visual Displays and Controls

� Levels of the Visual Factory

� More on Visual Displays

� More on Visual Controls

� Examples of Visual Displays and Controls

� Using the Development Chart to create Visual Displays and Controls

MASS LEAN CULTUREThe Visual Factory Pyramid

Workplace Workplace

Organization and Organization and

StandardizationStandardization

Share Share

InformationInformation

Prevent Prevent

Defects Defects

and Errorsand Errors

Visual Visual Display

Display

Visual Visual Control

Control

5 S5 S

MASS LEAN CULTURELevels Of The Visual Factory

Share InformationShare Information

Share Standards at the SiteShare Standards at the Site

Build Standards into the WorkplaceBuild Standards into the Workplace

Warn about Abnormalities Warn about Abnormalities (Build in alarms)(Build in alarms)

Stop Abnormalities Stop Abnormalities (Prevent defects from (Prevent defects from

moving on)moving on)

Prevent Prevent Abnormalities Abnormalities (Error(Error--Proof)Proof)

Visual

Visual

Display

Display

Visual

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Visual

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Sort, Stabilize, Shine, Standardize, and SustainWorkplace Organization

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115 S’s

MASS LEAN CULTURE

Levels Of The Visual Factory (cont.)

Share InformationShare Information

Share Standards at the SiteShare Standards at the Site

Build Standards into the WorkplaceBuild Standards into the Workplace

Warn about Abnormalities Warn about Abnormalities (Build in alarms)(Build in alarms)

Stop Abnormalities Stop Abnormalities (Prevent defects from (Prevent defects from

moving on)moving on)

Prevent Prevent Abnormalities Abnormalities (Error(Error--Proof)Proof)

Visual

Visual

Display

Display

Visual

Contro

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Visual

Contro

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Sort, Stabilize, Shine, Standardize, and SustainWorkplace Organization

22

115 S’s

MASS LEAN CULTURE

• Communicate information and/orbuild controls into the work place andprocess so that activities areperformed according to standards.

• Make up the top four levels of the pyramid.

• Communicate important information,but do not control what people ormachines do.

• Make up the first two levels of thepyramid.

Visual Displays

Definition: Visual Displays And Controls

VisualControls

MASS LEAN CULTUREExamples of Levels One and Two

� Level 1:Standards are indicated separately. Meters read according to a check sheet.

� Level 2: Standards on labels. Meter readings can be compared to labels.

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Check Sheet

MASS LEAN CULTUREThe Concept Of Visual Control

� Ideal: Standards are totally integrated with action so that deviations from standards are impossible.

Get the correct control as close to the Get the correct control as close to the potential error as possible.potential error as possible.

MASS LEAN CULTUREExamples of Levels Three and Four

� Level 3: Visual indicator of standards are built into meters.

All conditions can be checked at a glance, standard is at 12 o’ clock.

� Level 4: A warning signal will activate in a non standard condition.

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MASS LEAN CULTURE

Example: Levels of Visual Displays & Controls

1. Share information Include reminder to remove key fromignition in owner’s manual

2. Share Standards at the Site Put sticker on driver window that says“Do you have your keys?”

3. Build Standards into the work place As the key is turned to the off position, acomputer voice says “Remove YourKeys!”

4. Warn about abnormalities Bell sounds when car door is opened ifkey is in the ignition

5. Stop abnormalities Door won’t lock if keys are in theignition

6. Prevent abnormalities Keyless entry to car can be used tounlock door (key pad on door)

Items to be Controlled Locking Keys in Car

MASS LEAN CULTUREExercise: The Six Levels

� Identify at least one common way to control behavior at a railroad crossing for each level of the Visual Factory pyramid.

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MASS LEAN CULTUREExercise: The Six Levels continued

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MASS LEAN CULTURE

� Brainstorm 10 minutes

MASS LEAN CULTURE

Manufacturing Engineer Roles and Responsibilities

� Keep line of sight for operators

� Tighten layouts to prevent build up of WIP inventory

� Provide Process Control Board Expertise

� Assist in work station/department redesign if needed

� Provide Error Proofing expertise