Applying Applying

““Visual Factory”Visual Factory” in thein the

Lean EnterpriseLean Enterprise

Lean Manufacturing:Lean Manufacturing:

“ “A systematic approach to Identifying A systematic approach to Identifying and and eliminating wasteeliminating waste through through continuous improvement by flowing continuous improvement by flowing the product at the pull of the the product at the pull of the customer in pursuit of perfection”customer in pursuit of perfection”

… … Center for Advanced ManufacturingCenter for Advanced Manufacturing

Purdue UniversityPurdue University

– Five Lean Fundamentals:Five Lean Fundamentals:

1.1. Identify Value from a customer’s Identify Value from a customer’s point of viewpoint of view

2.2. Map and measure the value stream Map and measure the value stream to eliminate waste (processes and to eliminate waste (processes and inventory / material)inventory / material)

3.3. Make the remaining steps “flow” Make the remaining steps “flow” (measure), reducing cycle time(measure), reducing cycle time

4.4. Let customers “pull” value (JIT)Let customers “pull” value (JIT)5.5. Pursue continuous process Pursue continuous process

improvement (measure)improvement (measure)

– Lean is Lean is VisualVisual• Measuring means nothing unless that Measuring means nothing unless that

which is measured is which is measured is communicatedcommunicated..• Multiple stakeholders act on the Multiple stakeholders act on the

displayed informationdisplayed information– Line workersLine workers– Line managementLine management– Line maintenanceLine maintenance– Quality controlQuality control– Quality assuranceQuality assurance– Industrial & Process EngineeringIndustrial & Process Engineering– ExpeditingExpediting– EtcEtc.

– Lean is Lean is Visual (cont’d)Visual (cont’d)• Employees are empowered – enough to Employees are empowered – enough to

stop the line. stop the line. They need to They need to seesee when when and whyand why..

• Teams and teamwork are key. Teams and teamwork are key. Let them Let them seesee their pace and another team’s. their pace and another team’s.

• Procedures are standardized. Procedures are standardized. Deviations from standard are Deviations from standard are displayeddisplayed..

• Lean events and tools use a data-driven Lean events and tools use a data-driven philosophy.philosophy. ( (DisplayedDisplayed) Data drives ) Data drives change / improvement.change / improvement.

• Andon BoardsAndon Boards::– Family of robust industrial displays Family of robust industrial displays

that integrate seamlessly with that integrate seamlessly with manufacturing intelligence & data manufacturing intelligence & data collection systemscollection systems

LCD DisplaysLCD Displays

• Industrial Flat Panel Monitors

• Higher Temp Specs than Dell

• Designed for 24 x 7 Operation

What might you measure?What might you measure?

• PeoplePeople- Output per labor hour- Output per labor hour- Direct labor per unit- Direct labor per unit- Indirect labor per unit- Indirect labor per unit- Units per hour or hours per unit- Units per hour or hours per unit- Overhead cost per unit- Overhead cost per unit

• ProcessProcess- Setup time- Setup time- On time delivery- On time delivery- Value added ratio- Value added ratio- Reject rate- Reject rate- Rework cost- Rework cost- First pass quality- First pass quality- Cycle time- Cycle time- Material Scrap- Material Scrap

• Reduce material scrap through Reduce material scrap through real-time parameter monitoring & real-time parameter monitoring & alerts.alerts.

• Early, remote warning alerts of Early, remote warning alerts of variance in critical processes.variance in critical processes.

• Instant availability of production Instant availability of production information for managers and information for managers and workers.workers.

• Team building/morale boostingTeam building/morale boosting.

• Quicker line changeovers.Quicker line changeovers.

• Real-time, broadcast display of line Real-time, broadcast display of line and employee production rates.and employee production rates.

• Reduce overages through Reduce overages through messages & alarms triggered by messages & alarms triggered by flow rate data, clock information, flow rate data, clock information, etc.etc.

• Safety alerts.Safety alerts.

• Increase team productivity by Increase team productivity by competitive performance competitive performance monitoring.monitoring.

• Replace whiteboard-style line Replace whiteboard-style line scheduling with automatic displays.scheduling with automatic displays.

• ““Central Station” monitoring of Central Station” monitoring of critical process parameters critical process parameters throughout the enterprise.throughout the enterprise.

Process for Implementing a solution

– Understand the metrics needed to measure.– Determine where the measurables come from.

• existing automation and process equipment | non-existent– Apply visual and sensing technology and propose a solution

• Sensors, HMI’s, push buttons, RFID tags– Layout of the facility

• Viewing distances• Viewing points

– Lines of information – Colors• Alarms

– Information access• Web access• Internal access

– Communications to higher system• SAP, ERP, WMS, • Middleware

Thank Thank you.you.