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The Visual Factory

The Visual Factory. Light It Up for Quality!. Why Visual Management?. How Do I Turn the Pump On???. Visual Management = Clarity. Make it clear. What to do That it was done correctly If something went wrong What needs to be improved. The Visual Factory Goes Even Further.

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The Visual Factory

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  1. The Visual Factory Light It Up for Quality!

  2. Why Visual Management? How Do I Turn the Pump On???

  3. Visual Management = Clarity Make it clear What to do That it was done correctly If something went wrong What needs to be improved

  4. The Visual Factory GoesEven Further Visual management (5S, etc.) Illumination + Indication Visual Factory

  5. Five Steps to the Visual Factory • Illuminate the work area • Use light-guided assembly when possible • Communicate process status to operators • Communicate status to supervisors • Communicate plant-wide status

  6. Light Up the Gemba • Gemba means “the real place” • Proper illumination drives up quality by revealing defects • Start by choosing an illumination level (lux) • Lux = lumens/m² • Example: 1000 lumen light over a 2 m² work surface = 500 lux

  7. Light Up the Gemba • Lux level required: • The Illumination Engineering Society recommended levels: Clear Daylight Overcast Daylight Hallway Twilight

  8. Light Up the Gemba • What is color temperature? • The temperature of a black bodyradiating a comparable hue tothe LED color • Higher temperatures (eg., 5000°K)are bluer (cool white) • Lower temperatures (eg., 2500°K)are yellower (warm white) • Why is it important? • Cool whites produce more contrastin general • For color-based inspections, the color temperature will be specified such as D50, meaning Daylight 5000°K

  9. What About Light Consistency? • The Illumination Engineering Society recommends no more than a 3:1 ratio of light intensity • You can get a quick read of this with a Lux meter app on your iPhone • See Megaman Lux Meter

  10. Why Use LED Lighting forWork Areas? • Flicker-free light • Highest efficiency (3 x lumens/W) • Long life (50,000 hrs) • Non-hazardous materials • Compact size • Higher color temp

  11. Use Light Guided Assembly

  12. Use Light Guided Assembly

  13. Use Light Guided Assembly

  14. Use Light-Guided Assembly Banner Offers Four Levels of Guide Lights Indicators with Sensor Arrays Indicators with Sensors Simple Indicators Indicators with Buttons

  15. Communicate Status within the Work Cell • The problem with traditional indicators is that they require a panel or enclosure and end up mounted away from the operator’s direct view • Banner indicators are designed for direct machine mounting • They can also be moved and adjusted for continual improvement

  16. Communicate Status within the Work Cell

  17. Human Factors Engineering • According to principles of Human Factors Engineering, visual indicators should be: • Conspicuous - mount them where they make sense, not simply where the electrical enclosure happens to be mounted • Unambiguous - indicators should befree of color when in the off state • Only EZ-LIGHTs can provide this. • The color goes to gray whenthe light is off • Reduces “visual clutter” Depending on the ambient lighting, it’s not immediately clear which lights are on and off

  18. Communicate Process Statusat the Cell Level • Banner tower lights and beacons arepre-assembled, so theycan be deployed quickly • Because they areLED-based, there is no need to take them apart and replace bulbs

  19. Use Wireless to CommunicateStatus Plant Wide • The sender and receiver of information are often separated by long distances • Wireless solutions are the fastest and most cost-effective way to make the link • Continuous improvement: “Decide carefully; implement quickly.”

  20. The Visual Factory Links People to the Process • The Visual Factory is the foundation ofall quality systems • It enables Kaizen, continuous improvement, by assemblers, supervisors and managers • Banner has the widest array of Visual Factory solutions available

  21. Thank You Questions?

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