VISUAL FACTORY

Visual Factory

Objectives
 Understand the value of lean
 Expand your level of knowledge
 Understand lean tools and how they impact each other
 Acquire an understanding of “best practices”
 Meet and discuss ideas freely with experienced persons
 “Network” with others who are also facing the challenge of
going back after this program and attempting to make a
difference
 Feel the fresh excitement of hearing in-depth about a new way
of doing business
 Prepare yourself for our next level of training available in the
Lean Manufacturing curriculum
Visual Factory - Agenda

 Unit 1  Unit 3
– Overview – Visual Factory Foundation
– Definitions – Visual Displays and Controls
– Main Elements – Levels of Visual Factory
– Error Proofing
 Unit 2
 Unit 4
– Why Use Visual Factory
– Visual Displays and the
– Elements of Production Visual Factory Pyramid
– Major Wastes and Controls  Unit 5
– Benefits of Visual Factory – Visual Controls
Unit 1

Overview
Instructional Goal

By the end of this training participants will

understand how the elements and techniques
of the Visual Factory System are used to
organize and control the workplace, ensure
adherence to standards, and promote effective
communication throughout the organization.

1-5
Overview of Visual
Factory

 Definition of Visual Factory

 How the Visual Factory can help you
 Three main elements of the Visual Factory
 Visual Factory vision and context
 Objectives of the Visual Factory

1-6
Definition: Visual
Factory

Visual Factory is the use of controls that will

enable an individual to immediately recognize
the standard and any deviation from it.

1-7
 What the Visual Factory
Will Do
ISO/QS-9000
Work Group Display DEPT A Compliant
Direction
Boards of Flow
Op # 10 20 30 40 50 60

Status
Indicators
Process Control Boards
Part Desc
Stop line Part Number
Pick next Fluid Level
Pick now Heat Sensor Markings
Stickers SCRAP

Indicator Lights Return to Job Aids

Supplier

Process
Direction of Marked Floor Gages
Rotation Areas
Showing
for Motors, Normal
Drives, Tables Color Coding Operating
of Parts Lubepoint Range
Identification
1-8
How the Visual Factory
Can Help You

 Reduce searching time

 Eliminate many frustrations
 Increase safety
 Improve communication
 Increase job satisfaction

1-9
Elements of the Visual
Factory

Visu Prevent
Con al Defects and
trol
Errors

V
Visiipssuual r ma tio n
D In f o
D layal
ispl Share
ay
5K
o rk place d
6 ey s
’S W
ti o n an
iz a
Organ rdization
a
Stand

1-10
The Visual Factory
Vision

 There is nothing extra

 The environment is immaculate, safe, and self-
cleaning
 Standards are easy to recognize and abnormal
conditions are easier to correct
 Performance and progress are readily apparent
 Zero Defects is a reality!

1-11
Context for the Visual
Factory

 Fierce competition requires both stringent control

and high flexibility
 In a visual factory, preventive controls stop defects
and other abnormalities at a single glance
 A visual workplace is transparent; we can recognize
waste and abnormalities at a single glance
 Workplace organization + visual displays and
controls = Visual Factory

1-12
Objectives of the Visual
Factory

Exposes
Abnormality
Elimination
Worker of Waste
Autonomy

Sharing

Information
Quick
Promotes Recovery
Prevention
Continuous
Improvement

1-13
Unit 1 Summary

 The Visual Factory

– Uses controls to help anyone recognize
standards
– Helps you in your job
– Reduces costs and improves quality
– Is shown in a pyramid

1-14
Unit 2

Why Use the Visual

Factory?
Why Use the Visual Factory
System?

 Five elements of production

 Major wastes control points
 Strategies of control
 Primary purposes and benefits

1-16
Five Elements of
Production

 Operators (man)
 Materials
 Machines
 Method
 Information

1-17
Major Wastes

Over-Production
Defects

Transportation

Over-Processing

Waiting

Motion
Inventory

1-18
The Six Control Points

 Safety
 Work Flow
 Inventory
 Equipment
 Quality
 Information

1-19
Strategies of Control

 Value-Added
 Just-In-Time Information
 Source Inspection
 The Three Actuals:
– Place
– People
– Process
 Visual Language

1-20
Strategies of Control: Value-
Added

Value-Added activities are those which add

form or function to the product. Any
activity that does not add form or function
is considered non value-added waste.

1-21
Eliminate Non Value-Added
Activity

Value
Added
Waste
Motion

Work

Incidental
Work

Categories of Work Motion

1-22
Strategies of Control:
Just-in-Time Information

The right information, in an appropriate

form, in the hands of the people who can act
on it, precisely when it is needed.

1-23
Strategies of Control: Source
Inspection

 Discover errors in conditions that create defects.

 Prevent errors from turning into defects.

1-24
Strategies of Control:
The 3 “Actuals”

 To be effective, process control, inspections and

information sharing must be understood in terms of
The 3-Actuals:
– The actual place an operation occurs
– The actual people in that place
– The actual process occurring in that place.

1-25
Strategies of Control:
A Visual Language

 Recognize problems and abnormalities

 Take quick corrective action
 Ensure necessary learning
 Prevent problems from recurring

1-26
Benefits of the Visual Factory System

 Reduces search time

 Eliminates defects
 Improves product quality
 Improves cost-effectiveness
 Improves communication
 Eliminates work frustrations and delays
 Increases workplace safety
 Increases job satisfaction among workers

1-27
 Unit 2 Summary

 Remember the five elements of production:

– Operators (man)
– Materials
– Machines
– Method
– Information
 Defects, waiting, and excess inventory are waste.

 Focus on Six Control Points to eliminate waste.

1-28
Unit 3

Visual Factory
Foundation

Intro 1
Visual Factory Foundation: Six Keys to
Workplace Organization

 Key 1: Sort (Organization)

 Key 2: Set In Order (Orderliness)
 Key 3: Shine (Cleanliness)
 Key 4: Standardize (Adherence)
 Key 5: Sustain (Self-Discipline)
 Key 6: Safety

1-30
Key 1: Sort
(Organization)

Distinguish Between What Is and Is Not Needed

1-31
Key 1: Sort - 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 is THIS used for?

1-32
Key 1: Sort - Red Tag
Holding Areas

 Temporary Storage
 Local Holding Area
 Central Holding Area
 Holding Area Manager
 Timely Clearing

1-33
Key 2: Set In Order
(Orderliness)

A Place For Everything

and
Everything In Its Place

1-34
Key 2: Set In Order - Location
Map Example

Extrude Form Cure

Cut

Press Dept. Pack

Office

1-35
Key 2: Set In Order -
Location Indicators

Location indicators are

used to indicate what is
located where and how
many are supposed to be
there.

1-36
Key 2: Set In Order

Guidelines For Location Indicators

To Indicate Locations Address Signboards

Limit Lines (Yellow)
Location Lines (White)
Labels

To Set Limits Height Lines (Red)

Standard Container Sizes
Red Coloring
To Indicate Danger
“Danger” Signs

1-37
Key 2: Set In Order -
Marking Standards

Examples: Pipes and Lines

Air ..............................................…..Blue
Water (City) ................................…..Brown
Gas ....................................................Black with White Band
Coolant ...........................................… Orange
Hydraulic Oil .................................… Green
Lubricating Oil ..............................… Red
Grease.............................................… White
Steam...............................................… Black with Yellow Band
Spindle Oil ..................................….. Yellow
Process Water ...............................… Purple
Refrigerant ....................................… Tan

1-38
Key 2: Set In Order -
Signs and Indicators

 Exercise:
– What signs and indicators would improve
communication and efficiency in this training
room?
– Pick one or two of the most important of these
and develop and implement prototypes.

1-39
Key 1: Sort
Key 2: Set In Order

 Summary
– Removing unneeded items makes it easier to find
what you need
– Relocating items can improve workflow
– Identifying item locations can help you find things
and put them back
– Together the first and second keys increase work
efficiency
– They also make your workplace a more pleasant
place

1-40
Key 3: Shine
(Cleanliness)

 Eliminate all forms of dirt

 Find ways to keep the workplace clean
 Adopt cleaning as a form of inspection
 Make cleaning a part of everyday work

1-41
Key 4: Standardize
(Adhere)

• Check
• Standardize
• Maintain
• Monitor
• Improve

Maintain and monitor the first three Keys

1-42
Key 5: Sustaining the 5S
Process

Requires self discipline

and commitment from
everyone in the organization

1-43
Unit 3

Visual
Displays &
Controls

Intro 1
Unit 3: Overview of Visual Displays
and Controls

 Introduction to Visual Displays and Controls

 Objectives of Visual displays and Controls
 Levels of the Visual Factory
 Explanation of Visual Displays and Controls
 Examples of Visual Displays and Controls

1-45
The Visual Factory
Pyramid

Visu Prevent
Con al Defects and
trol
Errors

V
Visiipssuual r ma tio n
D In f o
D layal
ispl Share
ay
5K
5K e o rk place d
eyyss W o n an
iz a ti
Organ rdization
a
Stand

1-46
Introduction: Visual Displays
and Controls

 Visual displays and controls are a system of devices,

information, color-coding, layouts and signboards,
standardized to create a common visual language in
the workplace
 They distinguish promptly between normal and
abnormal conditions
 They make abnormalities and waste obvious enough
for anyone to recognize
 They constantly expose needs for improvement

1-47
Levels of the Visual Factory

6
Prevent
Abnormalities
(Error-Proof)

5 Stop Abnormalities
(Prevent defects from moving
l
ro

on)
nt
Co

4 Warn about Abnormalities (Build

al

in alarms)
su
Vi

3 Build Standards into the Workplace

ay
pl
is

Share Standards at the Site

D

2
al
su
Vi

1 Share Information

WORKPLACE
Sort, Set, Shine,ORGANIZATION
Standardize, and Sustain
Workplace Organization

1-48
Definition: Visual Displays
and Controls

Visual Displays...
 Communicate important information, but do not
control what people or machines do. They make
up the first two levels of the pyramid.

Visual Controls...
 Communicate information so that activities are
performed according to standards. They
make up the top four levels of the pyramid.

1-49
Levels of Visual Control:
Example

Item to be controlled Ensuring that automobile lights are switched off

when driver cuts engine and leaves car

Include instructions to switch off lights before

Level 1-Share information turning engine off in the owner’s manual

Paste instructions on car dashboard so they can easily

Level 2-Share standards at
be seen by driver “Switch off lights before leaving
the site
car”
Level 2-Build standards into “Switch off lights” comes up in red on control panel
the workplace when the ignition is switched off

Level 4-Warn about Bell sounds when car door is opened if lights are on
abnormalities
Keys cannot be removed from ignition until lights
Level 5-Stop abnormalities are switched off

Level 6-Prevent abnormalities Lights are automatically switched off when car engine
turns off

1-50
Exercise:
The Control Pyramid

We can control behavior at

a railroad crossing in a number 6
66
of ways. Identify at least one 5 5 66
common way to control 55
4 5
behavior for each 3
level in the pyramid. 2
1

1-51
Visual Displays and Controls

 Signboards This and only this belongs

right here

 Material flow card 8421-0102

Status Board

 Status Boards Op#

Status
10 20 30 40 50 60
0 0 0 0 0 0

1-52
Visual Displays and
Controls (Cont’d)

 Red tagging

 White line demarcations

 Red line demarcations

1-53
Visual Displays and
Controls (Cont’d)

Standardized Work Sheet

 Standardized worksheet 1) Receive block

2) Add bolts
3) Check torque
4) Finish load,
and return

 Defective item displays

 Error prevention boards

1-54
Error-Proofing and the
Visual Factory

 Error-proofing expands the Visual Factory tool

kit to include methods that
– Broadcast information to problem solvers
– Prevent defects and abnormalities from
causing further problems
– Eliminate the possibility of certain problems
altogether

1-55
Error Proofing and
Visual Factory

Visu Prevent
Con al Defects and
trol
Errors

V
Visiipssuual r ma tio n
D In f o
D layal
ispl Share
ay
5K
5K e o rk place d
eyyss W o n an
iz a ti
Organ rdization
a
Stand

1-56
 Error-Proofing
Devices

Common Electrical Devices Common Mechanical Concepts

Limit Switch Define part positioning

for a process

Proximity Switch Allow only correct parts

to pass for further
processing

Microswitch
Enforce correct
assembly

1-57
Unit 3 Summary

 Visual displays and controls create a common

visual language in the workplace
 Visual displays communicate information but,
do not control workflow. (Levels 1-2)
 Visual controls control how activities are
performed. (Levels 3-6)

1-58
Unit 4

Visual
Displays

Intro 1
How to Develop
Visual Displays

 Definition of Visual Displays

 Visual Displays and the Visual Factory pyramid
 Integrating standards into the workplace
 Types of Visual Displays
 Developing Visual Displays in the workplace

1-60
Definition of Visual Display

 Everything that informs, directs, warns

tracks...
 Communicates standards
 Shows goals and results of activities and
improvements
 Communicates other information

1-61
Visual Displays and the Visual
Factory Pyramid

6
Prevent
Abnormalities
(Error-Proof)

5 Stop Abnormalities
(Prevent defects from moving
l
tro

on)
on

4 Warn about Abnormalities (Build

C
al

in alarms)
su
Vi

3 Build Standards into the Workplace

ay
pl
is

Share Standards at the Site

D

2
al
su
Vi

1 Share Information

WORKPLACE
Sort, Set, Shine,ORGANIZATION
Standardize, and Sustain
Workplace Organization

1-62
About Visual Displays

Communicate important
information but do not control
VISUAL what people or machines do.
DISPLAYS
Fall into the first two levels of
the Visual Factory pyramid.

1-63
 Integrating Standards Into
the Workplace

 Level 1: 30 30 30
20 40 20 40 20 40
– Standards are indicated 10 50 10 50 10 50
separately. Meters read
according to a check Month/Date

sheet.
 Level 2: Check Sheet

– Standards on labels. 20
20
30
30
40
40 20
30
40 20
20
30
30
40
40
Meter readings can be 10
10 50
50 10
10 50
50 10
10 50
50
compared to labels.
20 +/- 3 35 +/- 3 10 +/- 3

1-64
Types of Visual Displays

 Signboards
 Storyboards
 Maps
 Photos
 Checklists
 Material Flow Cards

1-65
Types of Visual Displays
(Cont’d)

Signboards Status Boards

Storyboards Standard Worksheets
Maps Defective Item Displays
Photos Improvement Data and
Checklists Progress Charts
Material Flow Cards

1-66
Developing Visual
Displays…

 Can solve many information and communication

problems
 Will increase work efficiency and effectiveness
 Will eliminate many work frustrations

1-67
Unit 4 Summary

 Recall that Visual Displays are devices that help

inform, direct, warn people in the workplace, or
track work activities.
 They fall into the first two levels of the Visual
Factory pyramid.

1-68
Unit 5

Visual
Controls

Intro 1
How to Use
Visual Controls

 Definition of Visual Controls

 Visual Control and the Visual Factory
pyramid
 Integrating standards into the workplace,
revisited
 Developing Visual Controls

1-70
Definition of Visual Control

Communicate important
information and standards in
VISUAL a way that controls
CONTROLS conformance to those
standards.

Fall into the top four levels of

the Visual Factory pyramid.

1-71
Visual Controls and the Visual
Factory Pyramid

6
Prevent
Abnormalities
(Error-Proof)

5 Stop Abnormalities
(Prevent defects from moving
l
tro

on)
on

4 Warn about Abnormalities (Build

C
al

in alarms)
su
Vi

3 Build Standards into the Workplace

ay
pl
is

Share Standards at the Site

D

2
al
su
Vi

1 Share Information

WORKPLACE ORGANIZATION
Sort, Set, Shine, Standardize, and Sustain
Workplace Organization

1-72
Visual Control

Get the correct information

or standard as close to the
point of action as possible.

 Ideal
– Standards are totally integrated with action so that deviations from standard are minimized.

1-73
Integrating Standards Into the
Workplace

 Level 1: 30 30 30

– Standards are 20 40 20 40 20 40

indicated separately. 10 50 10 50 10 50

Meters read Month/Date

according to a check
sheet. Check Sheet

 Level 2: 30 30 30

– Standards on labels. 20 40 20 40 20 40

Meter readings can 10 50 10 50 10 50

be compared to 20 +/- 3 35 +/- 3 10 +/- 3

labels.
1-74
Integrating Standards Into the
Workplace

 Level 3:
20 10
– Visual indicator of 10 30
30 40
20
standards are built into 40
20 50
50 30
meters. All conditions 50 10 40
can be seen checked at a Month/Date

glance, standard is at 12
o’clock.
 Level 4: Check Sheet

– A warning signal will 30 30 30

activate in non-standard 20 40 20 40 20 40

conditions. 10 50 10 50 10 50

20 +/- 3 35 +/- 3 10 +/- 3

1-75
Developing
Visual Controls

 Visual Controls, like Visual Displays, can resolve

many information and communication problems
in the workplace.
 Again, the result is improved work efficiency and
effectiveness.
 Another important result is fewer work
frustrations and a more satisfying work
experience.

1-76
Summary

 Recall that Visual Controls are devices that

communicate standards in a way that controls
conformance to those standards.
– They fall into the top four levels of the Visual
Factory pyramid.

1-77
Summary (cont.)

 Context of Visual Factory training

 Overview of the Visual Factory System
 Why Visual Factory is being implemented
 Workplace Organization and Standardization
 Overview of Visual Displays and Controls
 Developing Visual Displays
 Developing Visual Controls

1-78
6’S and VISUAL FACTORY

STATUS BOARDS – MULTIPLE ENTRY OF SAME INFORMATION (3 TIMES = AF

STD G081 / LOCAL EXCEL / CHINGA / STATUS BOARD)
1-79
6’S and VISUAL FACTORY
BEFORE AFTER

BEFORE AFTER

LEAN 6’S RED TAG HOLD AREA – INVENTORIED /

COMMUNICATED AND TO BE CLEARED OUT
1-80
6’S and VISUAL FACTORY
BEFORE AFTER

BEFORE AFTER

Engine Stand 6’S Improvement – Set standard conditions on all 4 Engine Stands

1-81
6’S and VISUAL FACTORY
BEFORE AFTER
BEFORE AFTER

6’S Cleaning Supply Storage Area – Relocated for ease of use and organized

1-82
6’S and VISUAL FACTORY
BEFORE AFTER

BEFORE AFTER

Safety Hazard Right Cowl Inspection Area – 2 Wing Stands

1-83
6’S and VISUAL FACTORY
BEFORE AFTER

BEFORE AFTER

Mule Storage Area – No Operator Clean Up Responsibility Plan

1-84