Visual controls: applying visual management to the factory
Gespeichert in:
| Hauptverfasser: | , |
|---|---|
| Format: | Buch |
| Sprache: | English |
| Veröffentlicht: |
New York [u.a.]
CRC Press
2011
|
| Schlagworte: | |
| Online-Zugang: | Inhaltsverzeichnis |
| Beschreibung: | XIX, 160 S. Ill., graph. Darst. |
| ISBN: | 9781439820902 1439820902 |
Internformat
MARC
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Datensatz im Suchindex
| _version_ | 1804149598897307649 |
|---|---|
| adam_text | Titel: Visual controls
Autor: Ortiz, Chris A.
Jahr: 2011
Contents
Introduction...........................................................................................xi
Acknowledgments...............................................................................xix
Chapter 1 Importance of the Visual Factory.....................................1
The Common Ground of Production Environments.............1
People.......................................................................................2
Processes..................................................................................3
Time.....................................................................................4
Human Interfaces..............................................................4
Engineering Changes, Expediting, and
Nonconforming Product.......................................................5
Inventory..................................................................................6
Raw Materials.....................................................................6
WIP Levels..........................................................................6
Finished Goods..................................................................7
The Bottom Line-Making Information Accessible.........7
Management s Role.....................................................................7
The Basics of the Visual Factory: 5S.........................................8
Visual Factory Layout.................................................................9
Visual Tools................................................................................10
Visual Parts and Supplies.........................................................12
Visual Maintenance and Total Productive
Maintenance Boards.................................................................14
Visual Communication............................................................15
Chapter 2 The Basics of the Visual Factory: 5S...............................17
The5S s........................................................................................17
Sort..........................................................................................18
Set in Order...........................................................................18
Shine or Scrub.......................................................................19
Standardize............................................................................19
Sustain....................................................................................19
vi • Contents
Let the 5S Event Begin.............................................................20
5S Day 1: Sort.......................................................................20
Sorting Team...................................................................20
5S Day 2 and Day 3: Set in Order and Shine.....................24
Position Floor Items.........................................................25
Create an Addressing System.........................................25
Organize Tools and Supplies..........................................27
Tool Board Basics.............................................................27
Shine and Scrub...............................................................29
5S Day 4: Standardize..........................................................29
5S Day 5: Beginning to Sustain...........................................31
5S in Maintenance Departments.............................................31
Tips for Sustaining 5S...............................................................32
Create an End-of-Day Clean-Up Procedure.....................32
Conduct a Daily or Shift Walkthrough.............................33
Establish a 5S Audit Sheet...................................................33
Create and Maintain a 5S Tracking Sheet.........................35
Develop a 5S Incentive Program........................................35
Chapter 3 Visual Factory Layout......................................................37
The Legacy of Factory Layouts................................................37
Visualizing Your Visual Factory............................................40
Actualizing Your Visual Factory........................................41
General Guidelines...............................................................41
Addressing Waste when Planning the Visual
Factory...........................................................................42
Overproduction...............................................................42
Waiting.............................................................................42
Motion..............................................................................43
Overprocessing................................................................43
Transportation................................................................44
Excess Inventory..............................................................45
Rejects and Scrap.............................................................45
Overall Sequence for Creating a Visual Factory
Layout..............................................................................46
The Four Basic Conditions of Value-Adding
Processes........................................................................47
Contents • vii
Value Is Being Added...........................................................47
Process Is Being Reconfigured (Setup or
Changeover)...................................................................48
Planned Stoppage..................................................................50
Unplanned Stoppage............................................................50
Visual Inventory........................................................................51
Feed Materials and Consumables......................................51
Purchased Inventory............................................................52
WIP.........................................................................................52
Finished Goods.....................................................................52
Laying Out Support Functions................................................53
Common Area.......................................................................53
Direct Support Functions....................................................53
Supervisory Personnel.....................................................53
Maintenance....................................................................54
Tooling..............................................................................54
QA.....................................................................................54
Planning............................................................................55
Indirect Support Functions................................................56
Materials Supply..............................................................56
Manufacturing Engineering.........................................56
Production Management................................................57
Product Engineering.......................................................57
Safety and Environmental Functions...........................57
Finance..............................................................................58
Plant Management...........................................................59
Sales....................................................................................59
Office Support Personnel...............................................60
Overall Support Services...............................................60
Back to Your Future Factory Layout......................................60
Chapter 4 Visual Tools......................................................................61
Visual Tool Boards or Shadow Boards...................................62
Tool Board Materials............................................................62
Designing and Constructing a Tool Board.......................63
Personal Tools: Dilemma or Solution?..............................66
Tool Check Cards................................................................68
viii • Contents
Positioning Tools Overhead.....................................................69
Right-Sizing................................................................................71
Chapter 5 Visual Parts and Supplies................................................77
Inventory Basics.........................................................................77
When We Use the Term Inventory, What
Specifically Are We Talking About?..................................77
Why Is Having More Inventory than What Is
Needed to Support Customer Demand a Bad
Thing?..........................................................................78
Why Does Your Company Carry Its Existing
Levels of Inventory?..............................................................79
Is It Possible to Drive Down Inventory Levels
without Putting Production and Shipping
Commitments in Jeopardy?...............................................80
What Role Does a Visual Management System Play
in Achieving a Reduced Inventory Level?........................80
A Few General Points on Supply Chain Management........80
The Role of Manufacturing Software Systems..................81
Current Global Trends.........................................................81
Receiving Inspection............................................................82
A Tour through the Ideal Stockroom.....................................82
Materials Common Area.....................................................83
Stockroom Entrance.............................................................83
Unloading Dock...................................................................84
Receiving Inspection Area..................................................85
Main Stockroom..................................................................86
Stockroom Layout Considerations....................................86
Factory Destination.........................................................87
Size and Weight................................................................87
Demand Volume..............................................................87
Inventory Reduction Strategy..................................................87
5S and Kanban.....................................................................88
5S in the Stockroom............................................................88
Incoming Parts Staging...................................................89
Receiving Inspection......................................................90
Supplies and Tools Area.................................................90
Parts for Production........................................................91
Contents • ix
Replenishment: Kanban and Two-Bin Systems................91
Setting Up a Kanban System..........................................91
Two-Bin Systems..............................................................93
Parts Bins and Color-Coded Labels..............................93
Two-Bin Team Exercise..................................................99
Chapter 6 Visual Maintenance and Total Productive
Maintenance Boards......................................................101
The Role of Maintenance........................................................101
Common Misconceptions.................................................101
First Responder...................................................................103
Impact of Product Nonconformities................................103
Total Productive Maintenance-An Overview...................106
The Three Approaches to TPM.........................................107
Proactive Maintenance.................................................107
Preventive Maintenance................................................107
Predictive Maintenance................................................108
The Three Levels of TPM...................................................108
TPM Level 1: Operators................................................108
TPM Level 2: Maintenance Technicians.....................109
TPM Level 3: Equipment Suppliers.............................110
Implementing TPM and TPM Visuals.................................Ill
Cross-Training.........................................................................115
Visual Layout for the Maintenance Area.............................116
Creating a Common Area.................................................116
Tools, Equipment, and Consumables Storage...........117
Measurement and Calibration Equipment.................118
Common Area Layout......................................................120
Maintenance Layout on the Production Floor..............120
Maintenance 5S...................................................................121
Visual Tool Boards.............................................................121
Personal Tools.................................................................121
Name Tags..........................................................................122
Maintenance Consumables and Kanban............................123
Overall Equipment Effectiveness..........................................125
The Maintenance Manager....................................................125
x • Contents
Chapter 7 Visual Communications................................................127
Facility Performance..............................................................128
Sales.....................................................................................128
On-Time Delivery...............................................................129
Productivity.........................................................................129
Quality..................................................................................129
Safety....................................................................................130
Environmental....................................................................130
Metrics Communication Boards at the Production
Level.......................................................................................131
Production Control Boards....................................................132
Communication Lights...........................................................135
Lean Procedures......................................................................136
Conclusion..........................................................................................139
Glossary...............................................................................................141
Index....................................................................................................147
About the Authors........................................................159
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| spelling | Ortiz, Chris A. Verfasser aut Visual controls applying visual management to the factory Chris A. Ortiz ; Murry R. Park New York [u.a.] CRC Press 2011 XIX, 160 S. Ill., graph. Darst. txt rdacontent n rdamedia nc rdacarrier Visuelle Kommunikation (DE-588)4131112-7 gnd rswk-swf Produktionsprozess (DE-588)4123984-2 gnd rswk-swf Produktion (DE-588)4047347-8 gnd rswk-swf Teamwork (DE-588)4126974-3 gnd rswk-swf Visualisierung (DE-588)4188417-6 gnd rswk-swf Management (DE-588)4037278-9 gnd rswk-swf Produktionsprozess (DE-588)4123984-2 s Visuelle Kommunikation (DE-588)4131112-7 s Management (DE-588)4037278-9 s DE-604 Produktion (DE-588)4047347-8 s Teamwork (DE-588)4126974-3 s Visualisierung (DE-588)4188417-6 s Park, Murry R. Verfasser aut HBZ Datenaustausch application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=025362355&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA Inhaltsverzeichnis |
| spellingShingle | Ortiz, Chris A. Park, Murry R. Visual controls applying visual management to the factory Visuelle Kommunikation (DE-588)4131112-7 gnd Produktionsprozess (DE-588)4123984-2 gnd Produktion (DE-588)4047347-8 gnd Teamwork (DE-588)4126974-3 gnd Visualisierung (DE-588)4188417-6 gnd Management (DE-588)4037278-9 gnd |
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| title | Visual controls applying visual management to the factory |
| title_auth | Visual controls applying visual management to the factory |
| title_exact_search | Visual controls applying visual management to the factory |
| title_full | Visual controls applying visual management to the factory Chris A. Ortiz ; Murry R. Park |
| title_fullStr | Visual controls applying visual management to the factory Chris A. Ortiz ; Murry R. Park |
| title_full_unstemmed | Visual controls applying visual management to the factory Chris A. Ortiz ; Murry R. Park |
| title_short | Visual controls |
| title_sort | visual controls applying visual management to the factory |
| title_sub | applying visual management to the factory |
| topic | Visuelle Kommunikation (DE-588)4131112-7 gnd Produktionsprozess (DE-588)4123984-2 gnd Produktion (DE-588)4047347-8 gnd Teamwork (DE-588)4126974-3 gnd Visualisierung (DE-588)4188417-6 gnd Management (DE-588)4037278-9 gnd |
| topic_facet | Visuelle Kommunikation Produktionsprozess Produktion Teamwork Visualisierung Management |
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