Applying “Visual Factory” in the Lean Enterprise

Lean Manufacturing: “A systematic approach to Identifying and eliminating waste through continuous improvement by flowing the product at the pull of the customer in pursuit of perfection” … Center for Advanced Manufacturing Purdue University

Five Lean Fundamentals: Identify Value from a customer’s point of view Map and measure the value stream to eliminate waste (processes and inventory / material) Make the remaining steps “flow” (measure), reducing cycle time Let customers “pull” value (JIT) Pursue continuous process improvement (measure)

Lean is Visual Measuring means nothing unless that which is measured is communicated. Multiple stakeholders act on the displayed information Line workers Line management Line maintenance Quality control Quality assurance Industrial & Process Engineering Expediting Etc.

Lean is Visual (cont’d) Employees are empowered – enough to stop the line. They need to see when and why. Teams and teamwork are key. Let them see their pace and another team’s. Procedures are standardized. Deviations from standard are displayed. Lean events and tools use a data-driven philosophy. (Displayed) Data drives change / improvement.

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LCD Displays Industrial Flat Panel Monitors Higher Temp Specs than Dell Designed for 24 x 7 Operation

What might you measure? People - Output per labor hour - Direct labor per unit - Indirect labor per unit - Units per hour or hours per unit - Overhead cost per unit Process - Setup time - On time delivery - Value added ratio - Reject rate - Rework cost - First pass quality - Cycle time - Material Scrap

Reduce material scrap through real-time parameter monitoring & alerts. Early, remote warning alerts of variance in critical processes. Instant availability of production information for managers and workers. Team building/morale boosting.

Quicker line changeovers. Real-time, broadcast display of line and employee production rates. Reduce overages through messages & alarms triggered by flow rate data, clock information, etc. Safety alerts.

Increase team productivity by competitive performance monitoring. Replace whiteboard-style line scheduling with automatic displays. “Central Station” monitoring of critical process parameters throughout the enterprise.

Lean beyond Manufacturing: Distribution Environmental Call Center Etc. Truck Forklift Driver Parts Packaging Calls Safety Flow, Target, Actual, etc.

Confirges the system enable the counters and defining the target times and production goals

Process for Implementing a solution Understand the metrics needed to measure. Determine where the measurables come from. existing automation and process equipment | non-existent Apply visual and sensing technology and propose a solution Sensors, HMI’s, push buttons, RFID tags Layout of the facility Viewing distances Viewing points Lines of information – Colors Alarms Information access Web access Internal access Communications to higher system SAP, ERP, WMS, Middleware

Thank you.