Plant Visual Management Practice
Zheng Simon, Li Hong Feb. 2008
I collect some good practice for visual management in different companies internal and external Lear. These idea considered both TS16949 & OEA requirement, I hope these idea can bring you benefit.
If any advance discuss and misunderstanding please feel free contact with me.
Ms. Li Hong firstname.lastname@example.org Office: 0086 431 84699020-126 M.B. : 13944187623
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. Foreword Welcome Board & Reception Floor Index Company Milestones QEHS Policy Entrance Product Introduction Exhibition Area Glass Decorated Information for the salary personnel Workshop Layout Workshop Layout with VSM Floor Identification Floor Identification Work Place Marked Slogan Identification with Color Identification for Material Identification for Verification and Quality Defect & Margin Sample Sample Management
22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. SRS Published Take Good Use of the Height Area Facilities for Material Employee Rest Area Company Suggestion System Restrict for Storage Safety Identification WI Sample Visal Management for FIFO Visal Management for Incoming Material Kanban Management Identificaton for Machines and Facilities Failure Mold and Actions for Important Machine Other identification for life area MOS Wall and Review Meeting Place MOS Wall and Review Meeting Place Action Plan Follow Up QRQC(Quick Response & Quick Control Visual Board Employee Skill Matrix
42. 43. 44. 45. 46. 47. 48. 49. Safety Information Bord Meeting Room Handbooks for QEHS and CI knowledge System Certificates and Award Show Area Red Light & Sign (Andon System) Andon Flash in Testing Workstation Andon Visal Board in Production Line With Best Practice
Welcome Board & Reception Welcome board with requirement to stay at our company. That can show both warm and restrict to the visitors
Fit for first floor
Fit for each floor
It’s better can be easy update with the plant growing up. back
QEHS policy, executive messages and others of Lear global philosophy should be pasted on very striking place back
Only the employee with pass card and registered personnel can come into the company, this idea also fit for the important place in the company such as lab or R&D area. Fire extinguisher hangs on the wall can save more time & more easy to get it. back
? Exhibition area have detail information of the product. ? Exhibition area need good lighting system for the show.
This fit for the meeting room or the glass door.
Information for the salary personnel
With this board, you can ? Know the difference team member with pictures and roles ? Know if the personnel is in the office and the absence reason ? know who is the absence deputy for the manager back
Workshop Layout with VSM
This is a good sample for workshop layout with flow chart and pictures, two or three documents are compositive into one, simple and clear. You also can connect with VSM analysis and improvement.
Traffic aisles & walkway respectively
On the pad also have Lear logo.
On the road, One-way or two-way traffic flow is defined.
Work Place Marked
1 Triangle style fit for see the mark at any direction. 2,3 Work place marked same style but use colour identification for difference function. back
Quality First 质量第一 Customer in your heart, Quality from your hand 顾客在你心中， 质量在你手中
Do it right the first time 第一次就把事情做对 Do not accept/Build/Ship the defect 不接受/不制造/不流出不合格品 Go site, See reality, Analyze actualities 到现场，看现物，分析现状 back
Identification with Color Colour is very useful in identification ?Used in different roles’ uniform ?Used for different shelf or box for status identification ?Used for material identification of project to prevent material mixture
Colour should be defined and have standard plate or else there will be too much colors in one company! back
Identification for Material
Red box area need every shift evaluation
Cutting area red box is footprint style, that can show’s with part need complement
The needle scrap should be managed very serious in sewing line, avoid break needle hidden in the seat cover.
Nonconformities should be separate with other parts.
Identification for Verification and Quality There are two side for one card, one side is green means Ok, the other is red means not Ok. Sometimes use for fist part and POKA-YOKA verification and everyday check place.
Below is no customer complain days, publish on the wall that all the people knows their R & R to extend that.
Defect & Margin Sample
Customer signed off margin sample when project released
A full of small holes war is very convenience to hang the small parts up
Small parts which hard to distinguish need physical sample back
Take Good Use of the Height Area 1 The small parts for maintain area. 2 Several checking fixtures hold in one shelf. 3 Facilities or tools put in one cabinet with several hatched layer and wheel, if the tools at the right position can easily readable. 4 In the lab so many testing requirement and report can put in a bag and the document title can be read at first glance.
Facilities for Material 1 Condign material trolly is good for keeping the parts quality. 2 Making the trolly orderly when they are not at same size. They can at the same length. 3 Make the same standard box for small parts and have a clear Label. The red box also need considered.
Employee Rest Area
1 Employee rest area can offer a beautiful area to have a rest. 2 On the shelf is the training materials that have been used before. Personnel can often review them.
Company Suggestion System
1 Every visitor can leave their comment for our company 2 Any employee can put their idea into General Manager mail box 3 Formal note for I suggestion can easy get to leave your golden idea.
Restrict for Storage
For the material in the warehouse or beside the production line, there is restrict quantifies. We also need think to restrict the height of the material.
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For many pages WI, these method is a good way to solve the layout problem, for operator also can easyly find their needed information. back
Visal Management for FIFO Colour management in FIFO
Good material layout to carry out FIFO
Visal Management for Incoming Material
Identificaton for Machines and Facilities
Failure Mold and Actions for Important Machine
Other identification for life area
MOS Wall and Review Meeting Place
Workshop MOS Indicator - Customer - internal - Supplier
MOS Wall and Review Meeting Place
? MOS Indicator
- Data Acumulate - Data Analysis dayly/weekly/monthly - Action Plan
Action Plan Follow Up
PDCA style action follow up mold. Job card can moveable from one stage to another.
8D report style with red-green lamp. One can easy read how on going for one action.
QRQC(Quick Response & Quick Control )
Visual board with picture, clearly and easy to understand
Employee Skill Matrix
Safety Information Bord
In meeting room hang up some company milestone and important corner of the workshop pictures to show the history and full of operation booming status.
Handbooks for QEHS and CI knowledge
System Certificates and Award Show Area
Red Light & Sign (Andon System)
Andon system fjor red light and sign can show whether the production line is smoothly or not. Sometimes also have the sound alarm together.
Andon Flash in Testing Workstation
There will have different colour when testing result shows different result, ok with green and not ok with red, at the same time not ok parts can’t moveable from the fixture.
Andon Visal Board in Production Line
With Best Practice
Any questions? Hope to help for you!