The Visual Factory

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

Condition Lux
Clear Daylight 10,000
Overcast Daylight 1,000
Hallway 100
Twilight 10
Full Moon 0.1
Application Recommended Lux
Warehouse 100
Work Area 150
General Assembly 1000
Detailed Assembly 2000
Fine Inspection 5000
8
Light Up the Gemba

• What is color temperature?
• The temperature of a black bodyradiating a
  comparable hue tothe LED color
• Higher temperatures (eg., 5000K)are bluer (cool
  white)
• Lower temperatures (eg., 2500K)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 5000K

9
What About Light Consistency?

• The Illumination Engineering Society recommends
  no more than a 31 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

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 operators 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, its 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?

22
(No Transcript)