A Visual Factory is a concept that uses visual signals to replace text-based communication in a workplace.
This method ensures quick and easy comprehension, making work instructions, safety guidelines, and other essential information more accessible and understandable for all employees. Visual tools include pictures, tags, labels, and signs that indicate control points, measurements, and ranges.
Table of contents
What is a Visual Factory?
A Visual Factory is a concept that emphasizes the use of visual signals to communicate information efficiently in a manufacturing environment. Instead of relying on text-based instructions, visual factory techniques use charts, signs, labels, and other visual tools to convey critical information.
This approach helps streamline operations, reduce errors, and improve overall efficiency.
Purpose of Visual Factory
The primary goal of a visual factory is to simplify communication within the workplace. By replacing text with visual cues, employees can quickly understand what needs to be done, where tools and materials are located, and how processes should be executed. This method leads to several benefits, including:
- Quick and easy access to instructions
- Reduced injuries and strain
- Increased efficiency and responsiveness
- Lower variability and non-conformity rates
- Decreased training time
Benefits of a Visual Factory
- Quick and Easy Instructions: Visual signals provide immediate understanding without the need to read lengthy manuals.
- Reduced Injuries and Strain: Clear visual instructions reduce the likelihood of accidents and physical strain.
- Increased Efficiency and Reactivity: Visual tools streamline processes, making operations smoother and more responsive.
- Reduced Variability and Non-Conformity: Consistent visual instructions help maintain quality and reduce errors.
- Decreased Training Time: New employees can quickly understand their tasks through visual guides, reducing the time required for training.
Scope of Visual Factory
The Visual Factory concept can be applied across various areas, including Health, Safety, and Environment (HSE), production, maintenance, and quality control (QC).
Visual Workplace
The Visual Workplace, also known as Visual Factory or Visual Management, is a lean concept that places critical information at the point of use.
Implementing visual tools throughout a facility can lead to higher productivity, reduced waste, and improved safety. Visuals are crucial for maintaining the success of lean manufacturing initiatives by reinforcing standards and enabling quick detection of abnormalities.
Creating Visuals
- Colour-Coded Shadow Boards: These boards help store tools and equipment at the point of need. Workers can easily see if a tool is missing and where it belongs.
- Storage Locations: Borderlines and labels clearly define storage areas, ensuring items are returned to their proper places.
- Emergency Egress Markings: Facilities should have marked exit paths and doors to ensure safe evacuation during emergencies, with glow-in-the-dark markings for visibility in low-light conditions.
Key Elements of a Visual Factory System
The key elements are:
Workplace Organization and Standardization (5S)
The foundation of a Visual Factory system is the 5S strategy:
- Seiri (Sort): Keep only necessary items.
- Seiton (Set in Order): Ensure everything has its place.
- Seiso (Shine): Maintain cleanliness.
- Seiketsu (Standardize): Standardize best practices.
- Shitsuke (Sustain): Foster a culture of discipline and continuous improvement.
Visual Displays for Sharing Information
Visual displays communicate important information and standards, making them visible and understandable to everyone in the workplace.
Prevention of Abnormalities Through Error Proofing
Visual controls help identify and prevent errors. They distinguish between normal and abnormal conditions, making it easy to spot and address issues promptly.
Essential Visual Factory Tools
The essential tools are discussed below:
Portable Printers and Benchtop Printers
Printing solutions are vital for creating custom visual displays and controls. These tools allow for the on-demand production of signs, labels, and charts tailored to specific needs.
Workstation and Area Lighting
Bright, adjustable LED lighting enhances visibility at workstations, improving productivity and ergonomics. Well-lit areas are easier to monitor and maintain, reducing the likelihood of errors.
Tower Lights and Indicators
Multi-segment LED tower lights provide clear, customizable indicators of machine and process status. These lights can signal various states, such as when a machine needs maintenance or when a process is complete.
Strip Lights and In-Line Lighting
Configurable strip lights and in-line lighting devices offer versatile illumination and status indication. These tools help operators quickly identify issues and maintain smooth operations.
Implementing a Visual Factory System
- Identify and Prepare the Area: Determine where the Visual Factory system will be implemented.
- Choose the Starting Point: Begin with a specific area or process.
- Follow the 5S Strategy: Organize and standardize the workplace.
- Implement Visual Displays and Controls: Use visual tools to communicate information and prevent errors.
- Visualize Standards and Abnormalities: Make standards clear and easily detectable.
- Conduct Periodic Reviews: Regularly review the Visual Factory system to identify areas for improvement.
- Standardize Changes: Implement and standardize any improvements.
- Communicate Desired Standards: Ensure that everyone understands the standards and how to maintain them.
Benefits of Visual Displays
A Visual Factory offers several benefits:
- Promotes Zero Defects: Maintains conditions for zero defects, failures, and waste.
- Shares Information: Makes all necessary information visible for effective control.
- Alerts to Abnormalities: Allows instant detection of deviations from standards.
- Aids in Quick Recovery: Enables swift correction of abnormal conditions.
- Promotes Worker Autonomy: Increases adherence to standards by making the system’s functionality clear.
- Supports Continuous Improvement: Encourages stakeholders to identify and implement improvements.
Final Words
Implementing a Visual Factory system can significantly enhance efficiency, safety, and quality in a workplace. By using visual tools, organizations can reduce the time spent searching for tools and information, minimize frustration, and improve overall productivity.
Visual Factory systems not only streamline operations but also foster a culture of continuous improvement and zero defects.
