Visual Management Systems
As processes become more complex, information exchange becomes increasingly critical. Visual management encompasses a range of tools for accurate, efficient communication, designed to turn conventional manufacturing settings into “visual factories.” “Andon lights” — illuminated devices which may resemble scoreboards or traffic signals — are often the centerpiece of the visual factory, conveying high volumes of real-time process information. Using simpler technologies, plant managers often post work instructions in production areas, using photos and other graphic elements to help minimize production errors. In the visual factory, information is delivered to inform, alert, or motivate production teams.
We implement visual management in two stages: first, determining what information must be conveyed, and, second, deciding how to communicate it.
Our consultants start by working with your team to compare the current state of your process with your desired goals. The information required to get from one state to another is what must be conveyed. Typically this information includes:
- Process metrics
- Work instructions
- General plant information
How the information is conveyed depends on the desired result. The display location and the means of delivery depend on the information’s relevance. Process metrics, for example, are typically displayed at the machine or manufacturing cell, while general plant information is usually posted in a central location where everyone has access to it.
Information is most effective when it is delivered in real time, and immediate feedback facilitates immediate improvement. The more visually (rather than verbally) information is displayed, the more communication will improve. In most cases our consultants use visual management tools to support a 5S effort. Lean manufacturing relies on two-way information exchange throughout the organization.
Benefits
With the help of visual management systems, your operation will:
- Reduce downtime
- Minimize operator errors
- Increase productivity