1. Applying
“Visual Factory”
in the
Lean Enterprise

2. 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

3. 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)

4. 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.

5. 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.

6. Andon Boards:
Family of robust industrial displays that integrate seamlessly with manufacturing intelligence & data collection systems

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

8. 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

9. 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.

10. 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.

11. 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.

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

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

20. 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

21. Thank you.