Visual Factory

IMPLEMENT 5 S SYSTEM

 Zero Waste

Visual Factory Benefits : Eight Zeros

Reduce cost & increase capacity

Zero Injuries
Improve plant safety & reduce absenteeism

Zero Downtime Losses

Less unplanned downtime

Zero Defects
Increase product quality & reduce variability

 Zero Waste in changeovers

Allows for more SKUs

Visual Factory Benefits : Eight Zeros

Zero Delays
Increase JIT deliveries

Zero Customer Dissatisfaction

Increases customer confidence & trust

Zero Red ink

Increases company profitability

PRINCIPLES
4 V isualize
4 I nform 4 S ignal

4 U nify
4 A udit 4 L ocalize

PRINCIPLES
Visualize
Inform
the adjustments, the levels, the lubrication points etc. on the equipments. with indicators, with standards, with diagrams posted in the shopfloors.

Signal by ground marks, by standardized

informations.

Unify Audit

the supplies, the documents etc. at the plant level. the shopfloor regularly with a cleaning and housekeeping audit policy.

Localize
shopfloor.

communication spaces in each

BUILDING BLOCKS OF T.P.M.

5Ss

SEIRI

SEITON SEISO SEIKETSU

SHITSUKE

SEIRI SEITON SEISO

- SORT - SET - SHINE

SEIKETSU - STANDARDISE SHITSUKE - SUSTAIN

Definitions...
SORT DISTINGUISH BETWEEN WHAT IS NEEDED AND WHAT IS NOT. SET A PLACE FOR EVERYTHING AND EVERYTHING IN ITS PLACE. SHINE CLEANING, LOOKING FOR WAYS TO KEEP IT CLEAN AND IDENTIFYING FAULTS. STANDARDISE TO STANDARDISE PROCEDURES AND AGREE WITH TEAM SUSTAIN

VISUAL MANAGEMENT IS NOT JUST SOME CLEVER TRICK TO GET PEOPLE TO PAY ATTENTION.

ITS ABOUT...
1. 2. 3. BEING ABLE TO FIND IT WHEN YOU NEED IT. KNOWING WHERE TO LOOK FOR IT. BEING ABLE TO SEE A PROBLEM BEFORE IT GETS WORSE.

YOU CANNOT EXPECT SERVICE DELIVERY TO ATTAIN THE HIGHEST STANDARDS IF WORKING CONDITIONS DO NOT SUPPORT FIRST CLASS PERFORMANCE

The First S SORT

Determine what is needed in the workplace and what is not needed Eliminate what is not needed

Eliminate the might come in usefuls

Red Tagging is a dynamic and visual way of determining between needed and unneeded items

RED TAGGING

Is this item needed? If it is needed, is it needed in this quantity? If it is needed, does it need to be located here? Once the items have been identified and tagged, they can be moved to the Red Tag Holding Area

RED TAGGING RULES

Be thorough & investigate everything Dont just look at objects, look in lockers cabinets etc Try for everyone to be able to tag at least 5 items Be hard on yourself and the workplace - no gain no pain Dont tag people Dont argue amongst yourselves if an item is useful or not at this stage

THE AUCTION
At this stage we go through every item as a team and decide whether to keep it or not.

THE SECOND S SET

ITS ABOUT INFORMATION.

WHAT INFORMATION DO YOU:

NEED TO KNOW NEED TO SHARE

THE HEART OF VISUAL MANAGEMENT IS A SIMPLE BUT POWERFUL QUESTION.

WHAT DO I NEED TO KNOW, WHAT DO I NEED TO SHARE?

APPLY THIS QUESTION IN RELATION TO THE FIRST DAY OF THE EXERCISE. NEED TO KNOW
WHAT DO YOU NEED TO KNOW TO DO YOUR JOB MORE EFFECTIVELY?

NEED TO SHARE
WHAT INFORMATION DO YOU NEED TO SHARE FOR YOU AND OTHERS TO BE MORE EFFECTIVE?

FOR PACKAGING MATERIALS WE CAN CLEARLY SEE . . .

WHERE? WHAT? HOW MANY?

USING VISUAL CONTROLS SO THAT ANYONE AT A GLANCE . . .

1. CAN SEE. 2. CAN TAKE OUT. 3. CAN RETURN.

OHP Screen

THE KEY 3 SPECIFICS TECHNIQUE

TOOL
1. LABELS, COLOUR CODING, NUMBERS, OBLIQUE LINES. 2. FIRST IN FIRST OUT F.I.F.O. STORAGE RACKS SYSTEMS. 3. TWO BIN SYSTEMS.

APPLICATION
ARRANGING LOCATIONS ON SHELF AND RACKING. PREVENTS AGE RELATED DETERIORATION ON STORED ITEMS. AUTOMATICALLY SIGNALS A LOW QUANTITY LEVEL AND ALLOWS TIME OF REFILL. OUTLINES ALLOW AT A GLANCE ADDRESS FOR TOOLS AND JIGS. AUTOMATICALLY RETURNING TOOLS TO SET ADDRESS.

4. SHADOW BOARDS.

5. SUSPENSION DEVICES.

ESTABLISHING WORKPLACE ADDRESSES ROAD SYSTEM? FACTORY WORK SITES LINE/SECTION

PROCESS
MACHINES/EQUIPMENT DOCUMENTS

NAME BADGES? THIS STRAGETY FOR SIGNS EXTENDS TO SMALL DETAILS SUCH AS PROCESS SIGNS, MACHINE SIGNS AND EVEN NAME TAGS ON WORKERS UNIFORMS. APPLY THE TWO KEY WORDS AND 3 POINTS AND 3 KEYS.

ESTABLISHING WORKPLACE ADDRESSES

Example - Fire Extinguisher
Highest Level Address Map and entry point to area detailing extinguisher location. Lower Level Address Large coloured display mounted high above extinguisher. Lower Level Address Triangular displays ensure information is visible from sides. Lower Level Address Profile display on wall indicates exact location. Lowest Level Address Clear labels on extinguisher indicate test and refill data.
MAP

FIRE EXTINGUISHER

FIRE POINT

G:\MRINSE\TPM.PPT

CURRENT
fig: V1

FUTURE

fig: V2

fig: V3

MAX MIN

fig: V4

Stages of progress toward visual control.

fig: V5 Stage 1

Standard values are entered on a sheet which is apart from the dials.

left :35 right : 54

40 30 20 50 60 30 20

40 50 60

Stage 2

Standard values are indicated on dials.

40 30 50 30

40 50

20

60

20

60

35
Stage 3

54

Standard values are indicated in color on the respective instrument, although each dial must be separately monitored.

40 30 20 50 60 30 20

40 50 60

Stage 4

One can compare to standard values with a mere glance, even from a distance.

50

60

40 30

Indicate tightened position with registration marks for critical bolts.

G:\MRINSE\TPM.PPT

KEY 1 KEY 2 KEY 3

ELIMINATE SEARCHING WASTE. MAKE THINGS EASIER TO GET AND USE. MAKE SURE THERES ALWAYS THE REQUIRED QUANTITY. MAKE THINGS EASIER TO PUT BACK. MAKE THINGS UNDERSTANDABLE AT A GLANCE. AVOID PRIVATE COLLECTIONS.

KEY 4 KEY 5

KEY 6

The Third S SHINE

Eliminate all dirt, dust and scrap Keep the workplace immaculately clean Adopt cleaning as a form of

inspection

Cleaning exposes abnormal conditions and corrects prefailure conditions

Cleanliness Maintenance

Discovery of abnormality or slight defect

Instant Maintenance
Operator immediately restores or improves upon the abnormality or slight defect

Requested Maintenance
If unable to immediately restore or improve upon the abnormality or slight defect operator :Flags abnormality Enters flag details on abnormality / improvement sheet

Once item is taken care of and its results confirmed the item should be checked off in the confirmation column and the flag retrieved

 5S is about the environment we work in NOT inside the machines. Examples of defects might be - missing lights - leaking pipes - missing manifold covers - damaged pillars

Cleaning Guidelines
List cleaning tasks in an efficient sequence Agree responsibilities Indicate where, when and what is to be cleaned specify methods or tools to be used Identify any checking criteria and corrective action to be taken

The Fourth S STANDARDISE

Standardise everything visually and ensure that any abnormalities can easily be recognised This S leads us to create visual controls These standards can be created by means of photographs and/or diagrams

The Fifth S SUSTAIN

These correct procedures have to become a lifestyle Training must be given to all involved in these correct procedures Regular workplace audits have to be completed by the people within the workplace

Visual Factory How to Develop

1. Target Area 2. Area Purpose & Function Identify the target area for Identify activities. Operations implementation & processes in the area 3. People 4. Implementation team Identify people who work or Identify the implementation need information in the area team 5. Workplace Organization 6. Identify Control Items Implement the 5 S system Identify problems, process, to organize the workplace. items or activities to be controlled 7. Identify facts & 8. Identify ideas information Contribute ideas how each of Identify facts, information, the items can be visually standards needed by the controlled people & their correct location

Visualize
F Goals :

the adjustments, the levels, the lubrication points etc. on the equipments.

4 Be able to control equipments (oil levels) without any tools.

4 Instantaneously control that suitable material (tools, adjustment pieces, cleaning material) is available and put back in its place.
4 Eliminate risk of mistakes during the dismantling and the re-assembling of parts. F Suggestions : 4 Guidemarks to adjust parts. 4 Color marking to fix equipment during changeovers (fig: V1). 4 Drawing the object on its location
(fig: V2).

4 Visualize lubrication points on the equipment or on a photography.

4 Narrow strips in front of the fans to visualize that they are running.
4 Plexiglass plate with marks
(fig: V3). (fig: V4).

4 Match marks on parts likely to loosen

4 Visualization of normal operating limits on control dials (fig: V5).

Inform
F Goals :

with indicators, with standards, with diagrams posted in the shopfloors.

4 To enable temporary workers and visitors to see and understand the standardization in use. 4 To have some synthetic diagrams in order to allow each team member to explain how the shopfloor runs to the new members, temporary members or visitors. 4 To have updated indicators in order to enable anybody to know the activity level and the performance of the shopfloor. F Suggestions : 4 Teams mission. 4 Teams photo. 4 Training planning board. 4 Attendance monitoring chart. 4 Safety boards with first aid workers photos & drawings of available safety protections. 4 Teams realizations summary. 4 Wipe out board for flash information.

Inform

with indicators, with standards, with diagrams posted in the shopfloors.

F Suggestions : 4 Team/Focus activity and performance indicators. 4 General plant KPI.

4 Schedule of current activities.

4 Shopfloor plans. 4 Equipment operating plan. 4 Equipment specifications (capacity, speed rate, ) 4 Finished products photos. 4 Diagrams showing the cost of material used. F Good practices : C Differentiate activity indicators (visualizing the level of activity) from performance indicators (visualizing the performance vs goals). C Plastify documents for a permanent use. C Make team members update most of the documents. C Controlling the updating of indicators should be an item of the shopfloor audit. C Each document temporarily posted should bear a date of removal.

Signal

by ground marks, by standardized informations.

F Goals : 4 Clearly signal the areas which have to stay cleared in order to reach the safety equipment easily. 4 Paint food path on the ground, to allow traffic in safety conditions. 4 Identify a location for everything, be sure that anything has its own location in order to quickly see what is untidy. F Good practices : C Respect the colors of ground marking (see board of standardization). C Indicate on notice boards in the shopfloors the standardization in use).

C Identify each storage area by writing on the ground the name of the stored material.

Signal

by ground marks, by standardized informations.

F Implementation : @ Organize a meeting with the team to explain the project. @ Photograph the current situation. @ Clearly define the limits of areas and draw a plan. It is essential that some common zones are integrated in the area chosen (spare parts storage, washing area ). @ Organize a specific operation to remove and eliminate unnecessary materials. @ Define with the team the ideal location for each thing and draw it on the area plan. @ Mark with a colored adhesive tape the location which has been previously defined. @ After a defined test period, validate the areas or change if necessary. @ Realize the definitive ground marking. @ Identify each storage area by writing on the ground the name of the stored material. @ Photograph the realizations.

Signal
pipes.

the nature of the fluids on all the

F Goals : 4 Instantaneously know the nature of the fluid running into the pipe (in case of dismantling or incident). 4 Know what is the fluid direction in order to prevent problems during the dismantling. F Good practices : C Respect the colors code for identification (see pipes identification exhibit). C Indicate by signs posted in the shopfloor, the standardization in use. C Indicate by direction signs on the pipes the fluids direction.

Unify

the supplies, the documents, at the plant level.

F Goals : 4 Reduce the costs generated by the differentiation. 4 Reduce the time spent on reading the documents by easily accessing to the searched information. 4 Facilitate the comparison between different indicators. F Suggestions : 4 Unify the oils and code them to be able to mark lubrication inlets with the type of oil to use. 4 Make a pre-printed format for the teams meeting minutes.

Audit

the shopfloor regularly with a cleaning and housekeeping audit policy.

F Goals : 4 Perpetuate, maintain the system. 4 Involve all workers of the shopfloor. 4 Have a support in order to train and inform people not belonging to the shopfloor. 4 Promote small but regular corrective actions to maintain or improve. F Good practices : C Define a standard trip to do the audit. C The evaluation sheet should allow to evaluate : $ the respect of the general and specific to the shopfloor safety rules. $ the level of the audited area cleanliness.

$ that there is a defined location for everything and anything has its own location.
$ the regular updating of all the indicators.

Audit

the shopfloor regularly with a cleaning and housekeeping audit policy.

F Good practices (cont) : C The evaluation sheet should allow to : - determine an index for cleanliness & housekeeping. - Jot down improvement suggestions. C There are 2 categories of criteria : 1. Safety criteria 2. Cleanliness criteria C A performance indicator should allow to : - see the performance level. - ensure the audit is done in conformity with the periodicity which has been previously defined. C Each audit has to be done by at least 3 people including 1 member & a team manager of the shopfloor. C During the audit, suggestions of improvements could be jotted down in the identified area. C All suggestions of improvements will have to be discussed in regular shopfloor meetings to decide and follow up the realizations.

Audit

the shopfloor regularly with a cleaning and housekeeping audit policy.

F Implementation : @ Meet all the team to explain the project. @ Determine the area to audit and draw a plan of it. @ Go over this trip with different people (teams, management, safety committee) and identify all points to be reviewed. @ Determine a periodicity (e.g 6 months) to update the evaluation sheet.

Localize
shopfloor.
F Goals :

communication spaces in each

4 Have a meeting point. 4 Create an exchange of up and down information. 4 Organize short meetings. 4 Provide functional diagrams, indicators etc. to facilitate explanations when solving a problem or presenting the shopfloor to a new member. F Suggestions : 4 Have a communication space for the plant (for temporary workers, visitors). F Good practices : C The communication space has to be painted in blue order to identify it. C Identify 3 specific parts into this space : e.g indicators / communication / business. C Have a permanent self service paper board. C Have a high table to facilitate taking notes or writing standing during small meetings.