Visual Tools For Kaizen Training Ppt

Slide 2

This slide provides information about the visual factory, a methodology in which multiple visual cues at the workplace or manufacturing plant are displayed. These cues are used to communicate information to employees or workers to improve efficiency, safety, and productivity. It also provides information about what should be displayed (process metrics, work instructions, and general plant information) and where to display it (walls, floors, machines, ceilings, and vehicles).

Instructor’s Notes:

Visual tools are used to share the following information:

• Process Metrics: Process metrics such as operating capacity, the voltage used, etc., are displayed on machines to provide information in real-time to ensure that required adjustments can be immediately made to a process
• Work Instructions: Work tasks instructions about what to do and when to do to minimize production errors. It also includes any instructions related to process safety, such as wearing protective gear
• General Plant Information: It includes visual information warnings related to any change, such as construction/digging sites, machine movements, and handling potentially dangerous material

Slide 3

This slide provides information on types of visual tools such as signs, posters, labels, floor markings, and charts. It also covers details of why to use these.

Instructor’s Notes:

Visual tools that are often used in the workplace are:

• Signs: Pre-printed or custom signs to display specific information. For example, a STOP sign displayed outside a prohibited area
• Posters: Posters are bigger in size and contain significant information. These are displayed to convey general instructions for safety or job procedures
• Labels: Labels are often placed for quick identification of machines and equipment
• Floor Markings: Floor markings are used to outline boundaries and provide direction to employees
• Charts: Charts are used to visually showcase quantitative information

Slide 4

This slide lists advantages of visual tools, such as reduced errors, increased employee morale, machine uptime, machine run rates, and decreased work-in-progress tasks.

Instructor’s Notes:

Visual factory allows organizations to disseminate information and deliver world-class performance. Its benefits are:

• Reduce Errors: Using signs, labels, and posters ensure no steps are forgotten and tasks are performed accurately. These also help reduce human errors and create a more efficient and safer workplace
• Increase Machine Uptime: Visual tools encourage reinforced learning, leading to perfect memorization of steps. Hence changeovers and maintenance tasks can be completed more quickly, leading to significantly higher machine uptime
• Decrease WIP (Work in Progress): Visual production cues such as charts help identify and remove bottlenecks to decrease work in progress (WIP) tasks
• Increase Machine Run Rates: Visual cues such as a color-coded calendar for scheduling machine maintenance and instructions about machine inputs result in higher machine uptime, leading to fewer machine breakdowns
• Increase Employee Morale: Well-displayed visual instructions (for complex tasks) give employees the confidence to do their jobs successfully. Also, using charts to display real-time data on a manufacturing plant’s shift motivates operators to achieve set targets, giving them instant feedback on their progress