Industries where factories are involved are always hectic workplaces where several processes are running at once. A specialized approach to visual management and Lean concepts is needed in these industries since there is such a strong emphasis on productivity, efficiency, safety, and sustainability. This helps to guarantee that operations operate smoothly while maximizing output.
In order to build a new standard of work, it can be challenging to strike this balance because every department, team, process, and measurement must be scrutinized to ensure that inefficiencies, errors, and restrictions are minimized. The visual work environment’s objective is to make everything self-explanatory. Clarifying progress, priorities, and standards will make them immediately obvious. By doing this, ambiguity about the way the task is being done and its state is avoided. Open communication is another aspect of lean. Even for suppliers and consumers who visit the work floor, no issues will be ignored. Everything is exposed and clear.
Why Visual Factory is a must?
The phrase “visual factory” is being widely used since it refers to a method of raising productivity and efficiency levels throughout your manufacturing operation and most probable reason being the safety. What exactly is a visual factory and how does it operate is the query. We’re giving you some helpful advice in this blog that will enable you to turn your work environment into a visual machine.
The information flow is changed by visual factory by reducing the size of the data bits and making them simpler to process. Most people learn more quickly from straightforward pictures than from a few sentences of text that briefly explains an idea. But in addition to learning more easily, they also typically pick things up more quickly. And for this reason, Visual Factory is a crucial component of the Lean methodology.
Visual factory is all about visual management which means Information is communicated visually using a variety of instruments, including message boards, safety posters, safety signs, floor markings, emergency evacuation plan, road markings, frames and panels for high-level signs, label holders, and information pockets.
Visual management is currently one of the most crucial foundations in the proper and successful application of 5S and Lean. You may easily use VisualMitra’s extensive selection of tools if you adhere to the Visual Factory philosophy. Let us have a look at some important reasons on why visual factory is required for you:
1] Each Department should be active visually
The entire idea behind a visual factory is to strategically deploy your visual management tools all across the space. These resources serve as visual clues that help team members achieve smooth work operations without any interruptions. It’s time to identify which types of visual tools will eliminate obstacles and restrictions if there are any areas of operations that continue to be slow or ineffective.
- The areas below can all be made more visually appealing to give you an idea of how this would be put into practice:
- Walls (visual management boards, KPI, shadow boards, Safety posters and signs)
- Floors (floor markings and freestanding stations for health and safety)
- Machinery (signage and safety instructions)
- Ceilings (pipe marking labels and hanging directing signage)
- Vehicles (safety signs and instructional labelling) etc. and many more…
There’s always room to explore more and make your factory appealing.
2] Establishing work standards
Visual management system facilitates the creation of work standards by monitoring and displaying data about the job being done. For instance, you can establish a regular pace if the work that has been completed is plainly visible. The same is true if you document a process’ steps in a visual format; this is known as standardizing work.
3] Customizing your visual aids is must.
Every factory or every workplace has its own way to ensure effectiveness. Even though some of the visual management tools in your visual factory may be generic, many of them will need to be customized. For instance, cleaning stations, PPE boards, shadow boards, and visual management boards can all be made specifically to meet the requirements of each department. By doing this, visual information is condensed to just provide what each team’s current needs are and also due to customization your visual aids becomes an identity of your company.
4] Regularly update key figures
Visual management system must be updated frequently if they are to provide a significant return on investment. Your staff will always have access to the most recent data by adding and updating information as it changes and they can rapidly become familiar with how the department is operating.
An effective, productive, safe, and successful visual factory depends on accurate information which is possible through visual boards or informative boards, which is why we’re here to help you get the most out of your visual management tools with customized training and coaching.
5] Keep in mind the fifth ‘S’
We can achieve a productive workplace by following the five phases outlined by the 5S system: sort, set in order, shine, standardize, and sustain. Many factories are able to implement the first four components, but they are unable to develop a sustainable system, which causes everything to finally revert to the earlier norms.
You may develop consistency and longevity by paying attention to how your visual factory functions. Training is crucial in this since your employees must feel comfortable using 5S and possess the necessary expertise to keep it running well.
6] Point out issues & Resolve issues
Visual management can be used to instantly alert people when something is incorrect. Automated systems for this can be extremely helpful for managers and employees alike because they free up time for other activities unless an issue is identified. When a problem is found, a signal is sent out so that they can swiftly address it before returning to their original task.
Problems can also be solved through visual management system. The problem will be resolved if there is a place or procedure in a facility where there is frequently confusion. Similarly, visual factory could prevent an issue from occurring in the first place by making it plain how to use a machine that workers frequently misuse.
7] Acknowledge future development
Your teams must continue to look for ways to streamline, improve, and enhance various processes even after the fifth “S” has been implemented. This calls for having a sharp eye for detail and being ready to make additional adjustments as and when necessary. Your organization won’t lag behind the constantly evolving needs of your customers, the larger industry, or your business if you incorporate the principle of continuous improvement into every aspect of your corporate culture.
What advantages does a visual factory offer?
By making data and information highly accessible and simple to understand, a visual factory avoids them from being secreted away on clipboards and inside computer systems. Consequently, you can consider the following advantages:
- Empowered workers who constantly have access to the information they need.
- Minimal interruptions, maximization of individual focus.
- Improved productivity through increased efficiency.
- Maximum production rates and product quality.
- Increased standards of safety and health.
- Tidy, well-organized work areas.
- Employee responsibility for putting tools back where they belong.
- Smoother collaboration boosts staff morale.
- Being in compliance with Government rules and regulations or labour laws.
It’s your time to create a Visual factory.
Are you prepared to establish an effective, successful, safe, and extremely profitable visual factory? Contact our team and we will show you how to harness the power of visual management.
To give those few crucial bits of information and show them in a visual and understandable way at the correct process step, at the right time, and to the right person or team, a visual control system requires cross-functional planning and implementation. Visualmitra are experts in this field for past 22 years, you can have a look at our company brochure to know more about us and what have we done in the field of visual management.