Visual Controls

Visual Controls: Applying Visual Management to the Factory

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Features

  • Explains how to develop a visual management system that enhances production activities
  • Provides step-by-step instruction on how to create visual shadow boards
  • Covers visual Kanban, material replenishment, and the implementation of a visual maintenance department
  • Explores the role of management in creating a sustainable Lean strategy

Summary

An effective visual communication system can help manufacturing employees eliminate significant waste from daily tasks. From work-zone color coding to posted metrics, visual controls clarify and simplify the path to enhanced processes and profits.

Leaving little to chance, Visual Controls: Applying Visual Management to the Factory provides a detailed explanation of how to apply the Lean principles of 5S to convert your factory to a fully functioning Visual Workplace. It covers the range of methods that collectively compose an effective visual management system and clearly explains management's role in creating a Lean strategy to accomplish the transformation. This book:

  • Considers visual Kanban, material replenishment, and the implementation of a visual maintenance department
  • Details management's role in implementing and sustaining a visual factory
  • Covers the range of visual tools—including tool boards, shadow boards, metrics communication boards, and tool check cards

From plant layout and department setup to visual tools and parts, this book facilitates the comprehensive understanding required to initiate positive change through visual communication. The authors supply authoritative insight on how to hasten the required cultural changes, as well as step-by-step instruction for creating visual shadow boards. They also highlight time-tested methods for measuring progress and performance with improved accuracy.

Table of Contents

Importance of the Visual Factory
The Common Ground of Production Environments
     People
     Processes
     Engineering Changes, Expediting, and Nonconforming Product 
     Inventory
     The Bottom Line—Making Information Accessible
Management’s Role
The Basics of the Visual Factory: 5S
Visual Factory Layout
Visual Tools
Visual Parts and Supplies
Visual Maintenance and Total Productive
Maintenance Boards
Visual Communication

The Basics of the Visual Factory: 5S
The 5S’s
     Sort
     Set in Order
     Shine or Scrub
     Standardize
     Sustain
Let the 5S Event Begin
     5S Day 1: Sort
     5S Day 2 and Day 3: Set in Order and Shine
     5S Day 4: Standardize
     5S Day 5: Beginning to Sustain
5S in Maintenance Departments
Tips for Sustaining 5S
     Create an End-of-Day Clean-Up Procedure
     Conduct a Daily or Shift Walkthrough
     Establish a 5S Audit Sheet
     Create and Maintain a 5S Tracking Sheet
     Develop a 5S Incentive Program

Visual Factory Layout
The Legacy of Factory Layouts
Visualizing Your Visual Factory
     Actualizing Your Visual Factory
     General Guidelines
     Addressing Waste when Planning the Visual
     Factory
Overall Sequence for Creating a Visual Factory
Layout
The Four Basic Conditions of Value-Adding
Processes
     Value Is Being Added
     Process Is Being Reconfigured (Setup or Changeover)
     Planned Stoppage
     Unplanned Stoppage
Visual Inventory
     Feed Materials and Consumables
     Purchased Inventory
     WIP
     Finished Goods
Laying Out Support Functions
     Common Area
     Direct Support Functions
Indirect Support Functions
Back to Your Future Factory Layout

Visual Tools
Visual Tool Boards or Shadow Boards
     Tool Board Materials
     Designing and Constructing a Tool Board
     Personal Tools: Dilemma or Solution? 
     Tool Check Cards
Positioning Tools Overhead
Right-Sizing

Visual Parts and Supplies
Inventory Basics
     When We Use the Term Inventory, What Specifically Are We Talking About?
     Why Is Having More Inventory than What Is Needed to Support Customer Demand a Bad Thing?
     Why Does Your Company Carry Its Existing Levels of Inventory?
     Is It Possible to Drive Down Inventory Levels without Putting Production and Shipping Commitments in Jeopardy?
     What Role Does a Visual Management System Play in Achieving a Reduced Inventory Level?
A Few General Points on Supply Chain Management
     The Role of Manufacturing Software Systems
     Current Global Trends
     Receiving Inspection
A Tour through the Ideal Stockroom 
     Materials Common Area 
     Stockroom Entrance
     Unloading Dock
     Receiving Inspection Area
     Main Stockroom
     Stockroom Layout Considerations
Inventory Reduction Strategy
     5S and Kanban
     5S in the Stockroom
Replenishment: Kanban and Two-Bin Systems

Visual Maintenance and Total Productive
Maintenance Boards
The Role of Maintenance
     Common Misconceptions
     First Responder
     Impact of Product Nonconformities
Total Productive Maintenance—An Overview
     The Three Approaches to TPM
     The Three Levels of TPM
Implementing TPM and TPM Visuals
Cross-Training
Visual Layout for the Maintenance Area
     Creating a Common Area
     Common Area Layout
     Maintenance Layout on the Production Floor
     Maintenance 5S
     Visual Tool Boards
     Name Tags
Maintenance Consumables and Kanban
Overall Equipment Effectiveness
The Maintenance Manager

Visual Communications
Facility Performance
     Sales
     On-Time Delivery
     Productivity
     Quality
     Safety
     Environmental
Metrics Communication Boards at the Production
Level
Production Control Boards
Communication Lights
Lean Procedures

Author Bio(s)

Chris Ortiz is the president and founder of Kaizen Assembly, a Lean manufacturing training and implementation firm in Bellingham, Washington. He has been practicing Lean for over 12 years and speaks around the country at trade shows and manufacturing expositions. He is the author of Kaizen Assembly: Designing, Constructing, and Managing a Lean Assembly Line (Taylor & Francis, 2006), Lessons from a Lean Consultant (Prentice Hall, 2008), Kaizen and Kaizen Event Implementation (Prentice Hall, 2009), and Lean Auto Body (Kaizen Assembly, 2009).

Kaizen Assembly has been featured on the show Inside Business with Fred Thompson that aired on CNBC and CNN Headline News. Chris is frequently featured in manufacturing trade magazines including Industrial Engineer, Industrial Management, Collision Repair Magazine, Metal Finishes, Assembly Magazine, and dozens of other industry-recognized publications. He has been trained by the John Costanza Institute of Technology in “Demand Flow Technology” and by the Georgia Institute of Technology for ISO 9001: 2000 Internal Quality Auditing. He is also a member of the Institute of Industrial Engineers and the Society of Manufacturing Engineers.

Murry Park is the founder of MRP ONE, a manufacturing consulting company located in Mount Vernon, Washington. As a 26-year veteran of manufacturing, Murry’s service has spanned roles from entry-level engineer to vice president and general manager to senior Lean consultant. His professional experience includes working with companies from various industries ranging from electronics to metals and aerospace to seafood and from small privately owned companies to larger publicly traded corporations across North America.

Internationally, he has observed and analyzed production processes in Argentina, Belgium, Italy, Japan, and Canada. Murry’s professional experience began in 1983 when volume batch processing was still considered vogue in American manufacturing. However, struggling with the realities of such an approach, he quickly recognized the merits of such new concepts as 5S, setup reduction, one-piece flow, and kanban, as he came to understand and apply them. Seeing immediate and dramatic improvements from every implementation, Murry became a lifelong student—and teacher—in the pursuit of sharing these concepts and methods with others. He has led countless improvement activities and has watched as serious value-adding enterprises embraced a culture of continuous improvement based on employee participation, thereby also enjoying the benefits that followed.

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