Tools & Techniques
Visual Management
Introduction of visual controls for inspection and checking can enormously simplify your inspection process and reduce inspection time. The aim of visual management is to create a visual factory where all inspections are carried out by the five sense organs. All instrument gauges should have colour marks to indicate the operating ranges, all valves should have open / close indicators, all pipe lines should have indication of direction of fluid flow, markings of pre-fixed locations for all items etc. These visual controls can simplify inspection and can reduce inspection time. The time spent on inspection can indicate the level of visual controls.
The benefits of visual management techniques are:
Increased ease of operation and inspection.
Reduced inspection time.
Abnormalities show up and are easily noticeable.
Less chances for operation and inspection errors
Improved safety
Increased awareness of activities
Reduced cost
Self inspired superior performance requires constant measuring and monitoring of the performance against competition and aspirations. Extensive use of visual management techniques through team communication boards, one point lessons etc. can inspire team members to continuously strive for the better.
Continuous Improvement
This process shall aim at:
Elimination of all losses affecting productivity, manpower efficiency, materials & energy.
Improvement of overall equipment effectiveness
Use of problem solving tools to eliminate chronic defects and imperfections methodically.
Systematically return equipment and production line to the performance standard of “new” equipment.
Involving all employees in improvement activities
Achieving full automation and unmanned production systems
Reducing cost
Improving ease of operation and safety
Respecting and implementing in-house ideas and innovations.
Achieving Zero breakdowns in equipment and production lines
Constant but continuous efforts in the right direction, to set things right through involvement of people in project teams is the theme of continuous improvement. Continuous improvement projects are identified and implemented by shop floor level project teams well coordinated by top management.
