INTRODUCTION

Lean Manufacturing Visual Factory is a term to describe how data and information is conveyed in a
lean manufacturing environment. In a lean manufacturing environment time and resources dedicated to
conveying information are considered as a form of waste, even though its essential. Use of visual
methods such as signs, charts and andons, enable easy access to the information & the current status of
all processes will be immediately apparent.
The more complex the process the more critical the exchange of information is to the process. Lean
Manufacturing Visual Factory is a set of tools that allow for accurate and efficient information
conveyance. Visual Factory is implemented in two stages determining what information needs to be
communicated and how this is accomplished.
Starting point of lean manufacturing visual factory is the identification on information, what needs to
be conveyed. The information required to get from one state to another is to be conveyed and the
current state must be compared to the future state goals in order to determine what information is to be
delivered. How the information is conveyed depends on the expected end result. The location and
method of information delivery also depends on the relevancy of the information. Typically this data
includes;
Process metrics- Process metrics are typically displayed at the machine or cell; therefore it is
most effective as it is delivered in real time. Immediate feedback facilitates immediate
improvement. E.g.: If light is used to indicate information it is referred to as an andon. Andons
are often the centerpiece of the lean manufacturing visual factory because it conveys
tremendous real-time process information.
Work instructions- Highly visual instructions with photographs and graphics will generally
minimize production errors. The more information can be conveyed visually the more it will
improve communication. Therefore work instructions are typically posted in the production
areas.
General plant information- Lean manufacturing relies on bi-directional information exchange
throughout the organization. In a visual factory environment information is delivered to inform,
alert and motivate. Therefore general plant information is typically posted in a central location
where everyone has access to it.
Lean Manufacturing Visual Factory Allows Companies to communicate and provide world class
performance. Thus the efficient timely communication allows organizations to function at their full
potential with added benefits such as;
Reduce Errors
Increase Employee Moral
Increase Machine Uptime
Increase Machine Run Rates
Decrease WIP (Work in Progress)



Visual Management
In the organizational world Visual Management is a management system that attempts to improve
organizational performance through connecting and aligning organizational vision, core values, goals
and culture with other management systems, work processes, workplace elements, and stakeholders,
by means of stimuli, which directly address one or more of the five human senses (sight, hearing,
feeling, smell and taste). These stimuli communicate quality information (necessary, relevant, correct,
immediate, easy-to-understand and stimulating), which helps people make sense of the organizational
context at a glance by merely looking around. It is a management approach that utilizes either one or
more of information giving, signaling, limiting or guaranteeing (mistake-proofing/ poka-yoke) visual
devices to communicate with doers, so that places become self-explanatory, self-ordering, self-
regulating and self-improving.
Selected place: Training Centre at a Garment Factory
Visual tools changes the training Centre to more visualized environment so that even a new employee
can be adjusted to working conditions use of visual controls. Itll give a positive picture on the factory.
Training room layout
The placement of the machineries can be marked using floor marks to guide the employees to place
them in an arranged layout. Also the different colour tapes can be used to mark necessary placements
of hazardous, scrap, working machineries, materials, etc. so that easy identification is possible.
















Special
Machines
Trainers & Supervisors lobby
Store
units
Display
unit

Machine bed arrangement
Machine bed can be arranged according to the machine type & the type of the operation. Few sample
machineries can be visually displayed as a poster or notice, so that everyone gets to know the
arrangement of common operations. This can be visually displayed using display boards at the training
Centre with procedures so that user can easily identify simple instructions of the procedure.



Visual Orders
Location identifiers for tools, parts, materials, product, equipment, etc can be used to create more
organized, clean & tidy environment. Pathways can be drawn, indication of each tool placement
places, first aid box , materials, folders, etc ease the work by ease of identification of lost tools, reduce
time for finding tools, etc. Even for a new trainee it will be easy to find any tools they need. Shadow
boards can be used to place all necessary tools required. Few examples were illustrated below.






Visual Standards & Visual aids
Display procedures and technical information at the point of use to ensure that best practices are
followed consistently by all employees. Quality procedures, GSD codes can be placed at the each
machine to aid the trainees to get used to standards. Needle break down procedure, Procedure of the
sewing operation, quality spec, etc can be used to aid them visually. Also for the basic trainees the
procedure of threading the machine, bobbin adjustment, etc. can be trained easily using visual
standards. Continuous access to these standards guides them to follow the standards.













Threading the machine
Threading bobbin winder

Visual equipment
Operator control labels, gauge indicators, inspection and service labels, hazard warning labels can be
used to facilitate training on autonomous maintenance.




Visual Matrics /Displays
Score boards, banners, learning curve displays, performance matrics, skill matrics for each trainee can
be displayed in each machine. It will help to each trainees improvements easily. A simple colour code
can be used to place on top of the
machine to indicate best
performers, average performers,
and weak performers.


Visual Safety
Proper equipment hazard labels, chemical labels, warning signs, accident prevention tags can be used
for necessary equipments, materials such as fusing machines, bonding machines, irons, etc.

Visual displays
Displays of company policy, workers safety rules, quality guidelines, etc. will control the people
visually by displaying the rules in wording or with the aid of signs. It enables the training on company
culture & working environment, etc. Information display/board also can be used to display all
necessary notices.







REFRERENCES

www.ptj.com.
Importance and need of ergonomics in the apparel industry by K.Saravanan (Pakistan
Textile Journal(2010)
Liff, S & Posey, P A (2004), Seeing is Believing: How the New Art of Visual
Management Can Boost Performance Throughout Your Organization, AMACOM, New
York.
Greif, M (1991), The Visual Factory: Building Participation through Shared
Information, Productivity Press, Portland.
Galsworth, G D (2005), Visual Workplace: Visual Thinking, Visual-Lean Enterprise
Press, Portland.