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MASS

LEAN CULTURE

MASS

Objectives:

LEAN CULTURE

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

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

LEAN CULTURE

MASS

Characteristics 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!

LEAN CULTURE

MASS

Elements Of The Visual Factory

Visu Con al trol Visu Disp al l ay 5S

Prevent Defects rs and Erro

Share n atio m r o f In place d k r o W an n o i t a iz Organ rdization a Stand

LEAN CULTURE

MASS

Brainstorm
Name

a large company that has an excellent reputation for quality and customer satisfaction. What would you expect to: • see • hear • smell • feel • taste if you visited this business?

LEAN CULTURE

MASS

Sort (Organization)

LEAN CULTURE

Distinguish Between What Is And Is Not Needed

MASS

Sort - Red Tagging
A

LEAN CULTURE

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

Apply Visual Factory...

LEAN CULTURE

MASS

Sort - Red Tag Holding Areas

•

LEAN CULTURE

Temporary storage

• Local holding area • Central holding area • Holding area manager • Timely clearing

MASS

Stabilize (Orderliness)

"A Place For Everything and Everything In Its Place"

LEAN CULTURE

MASS

Shine (Cleanliness)
Eliminating
Finding

all forms of contamination

ways to keep the workplace clean


Adopting

cleaning as a form of inspection


Making

LEAN CULTURE

cleaning part of everyday work

MASS

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

Maintain and monitor the first three Keys

LEAN CULTURE

MASS

Sustain (Self-Discipline)


Correct procedures are a part of the Manufacturing process.




The workplace is well ordered according to agreed upon procedures




Workers are properly trained







Everyone has adopted Visual Factory

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

LEAN CULTURE

How to Use Visual Displays And Controls
Overview
Levels

LEAN CULTURE

of Visual Displays and Controls

of the Visual Factory


More

on Visual Displays


More

on Visual Controls


Examples
Using

MASS

of Visual Displays and Controls

the Development Chart to create Visual Displays and Controls

MASS

The Visual Factory Pyramid

Visu Con al trol Visu Disp al l ay 5S

Prevent Defects rs and Erro

Share n atio m r o f In place d k r o W an n o i t a iz Organ rdization a Stand

LEAN CULTURE

MASS

Levels Of The Visual Factory

6

Prevent Abnormalities (Error(Error-Proof)

Vi su al

Co nt ro l

5 Stop Abnormalities

(Prevent defects from moving on) Warn about Abnormalities (Build in alarms)

4

Build Standards into the Workplace

V Di i su sp a l la y

3

5

S’ s

2

Share Standards at the Site 1

Share Information

Sort, Stabilize, Shine, Standardize, and Sustain Workplace Organization

LEAN CULTURE

MASS

Levels Of The Visual Factory (cont.)

6

Prevent Abnormalities (Error(Error-Proof)

Vi su al

Co nt ro l

5 Stop Abnormalities

(Prevent defects from moving on) Warn about Abnormalities (Build in alarms)

4

Build Standards into the Workplace

V Di i su sp a l la y

3

5

S’ s

2

Share Standards at the Site 1

Share Information

Sort, Stabilize, Shine, Standardize, and Sustain Workplace Organization

LEAN CULTURE

MASS

LEAN CULTURE

Definition: Visual Displays And Controls Visual Displays

• Communicate important information, but do not control what people or machines do. • Make up the first two levels of the pyramid.

Visual Controls

• Communicate information and/or build controls into the work place and process so that activities are performed according to standards. • Make up the top four levels of the pyramid.

MASS

Examples of Levels One and Two


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




30 20

50

10

20

40 50

10

20

40 50

10

Month/Date

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

30

30 40

LEAN CULTURE

Check Sheet

30 20 10

30 40 50

20 +/- 3

20 10

30 40 50

35 +/- 3

20 10

40 50

10 +/- 3

MASS

The Concept Of Visual Control Get the correct control as close to the potential error as possible.


Ideal:

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

LEAN CULTURE

MASS

Examples of Levels Three and Four 30




Level 3:

40

40

40

40

10

30

50

50

20

50

20

30

40

10

50

10

20

10

30 50




20

20

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

50

10

10

Visual indicator of standards are built into meters.

40

20

30

30

Level 4:

40

40

50

10

30

50

50

20

40

20

30

30

10

20

10

A warning signal will activate in a non standard condition.

LEAN CULTURE

Example: Levels of Visual Displays & Controls

MASS

Items to be Controlled

Locking Keys in Car

1. Share information

Include reminder to remove key from ignition in owner’s manual

2. Share Standards at the Site

Put sticker on driver window thatsays “Do you have your keys?”

3. Build Standards into the work place

As the key is turned to the off position, a computer voice says “Remove Your Keys!”

4. Warn about abnormalities

Bell sounds when car door is opened if key is in the ignition

5. Stop abnormalities

Door won’t lock if keys are in the ignition

6. Prevent abnormalities

Keyless entry to car can be used to unlock door (key pad on door)

LEAN CULTURE

MASS

Exercise: The Six Levels
Identify

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

6 5 4 3 2 1

LEAN CULTURE

MASS

Exercise: The Six Levels continued

6 5 4 3 2 1

6 6 5 5 6 66 5 55

LEAN CULTURE

MASS




Brainstorm 10 minutes

LEAN CULTURE

Manufacturing Engineer Roles and Responsibilities
Keep

MASS

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

LEAN CULTURE