THE IMPACT OF WORLD-CLASS MANUFACTURING PRACTICES ON SMALL MANUFACTURERS - by
David K. Johnson

Visual Signals

Visual controls and signals are used throughout a lean facility. These signals are used for communication purposes. Kanbans for example are used to communicate what to produce and when to produce it. Visual signals used for setup reduction might have a different color painted on each of the different bolt sizes as well as their corresponding wenches. Another visual signal might communicate which tools are missing and where each tool should be put away, by outlining the shape of each tool in its storage location. The most effective visual signals are simple and intuitive. They allow the employees to gather the needed information with a quick glance.

Process Standardization

Process standardization reduces variation and fosters continuous improvement. Variation in process flow significantly increases the complexity of production scheduling. By standardizing their processes, manufacturers are able to reduce both their operating complexity as well as cycle time variation, which must be buffered by inventory. Not only does standardization reduce variation in process flow, but it also reduces variation in product attributes, thereby increasing product quality. Variation due to a lack of standardization can also mask the inherent process variation making it difficult to identify the factors that influence process variation. This hinders continuous improvement efforts to track down the causes of process variation.

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Copyright © 2005. David K. Johnson. All Rights Reserved.