LEAN

MANAGEMENT
ASSIGNMENT
2

Submittedto: Mr. Bikas Agraw al

Submittedby:ManishChauha n
Mehuli Mukherje
eSuhana Choudh
ury
 OBJECTIVE

To explore the visual factory concept for implementation in

their environment and prepare a report on the same. The
environment chosen can be in the vicinity of the institute or
within the institute itself.
 LOCATION CHOSEN AS:

KD KNITTING LABS - NIFT KOLKATA

WHAT DO WE UNDERSTAND
BY VISUAL FACTORY

DEFINITION The term “visual factory” refers to an approach to lean

manufacturing processes based on visual information
throughout the workplace. A visual factory uses a system of
communication tools to share information at the time and
place it is needed.
Visual controls improve working areas by answering questions;
identifying equipment, materials, and locations; describing
actions and procedures; and providing safety warnings and
precautionary information. Visual tools also boost productivity by
giving employees the information they need, where and when
they need it.
 REQUIREMENT OF SEITON OR SET
IN ORDER

PROBLEM

Tools are kept haphazardly and in a very un-organised

manner. It is completely cramped at one place, hence
greater searching time in order to locate the tools

SOLUTION
5S tool- " SEITON" OR SET IN ORDER by
using a shadow board can be effective
or use of organizer tool box. it will be
time saving and easy to locate.
 REQUIREMENT OF LABELS, SIGNS AND
INSTRUCTIONS
PROBLEM
No labels on different kind of yarns to identify or
recognise them. All yarns have been placed
haphazardly on the shelves without any colour or type
coordination.

SOLUTION
By applying 5S tool Sort or " SEIRI". Seiri is sorting
through all items in a location and removing all
unnecessary items from the location.
Proper sorting of the yarn reel according to type will
reduce time consumption in finding.
Reduce time loss looking for an item by reducing the
number of unnecessary items. Simplify inspection.
PROBLEM
Machines and eqipments are not
labelled properly.

SOLUTION

Labelling each machine in the lab

mentioning its features. Also, caution
and danger labels are very important to
ensure safety of students and workers.
 REQUIREMENT OF
WARNING/ PRECAUTION SIGNAGES
AS SAFETY PRECAUTIONS

PROBLEM

No warning signs with respect to usage

of machines/equipments, or fire
fighting
SOLUTION signs.

Putting up fire extinguisher and signboard as

safety measure.
 REQUIREMENT OF FLOOR MARKING

PROBLEM
No proper floor markings make it difficult to walk
through the lab and different working cells cannot be
distinguished.

SOLUTION
Floor marking using coloured tapes to
demarcate the work areas.
 REQUIREMENT OF SEISON OR SHINE

PROBLEM
Chairs are not arranged in a proper
way, unclean workplace with
scattered threads, improper space
utilization. Very small bin for
disposal of the wastes

SOLUTON
5 S tool- " SEISO" OR SHINE improve workplace
organisation, and space utilisation i . e. cleaning
the floor, removing the waste into dustbin by
providing proper disposal equipment and
arranging the chairs.
 IMMEDIATE REPAIR OF FLOOR TILES
REQUIRED

PROBLEM
Floor tiles near important machines are
broken hence chairs cannot be placed
near such machines

SOLUTION

Immediate repair of floor tiles is necessary

since clean floors and proper flooring provide a
healthy environment for students to work in.
REQUIREMENT OF SEIKETSU OR
STANDARDIZE

PROBLEM

Display of work processes and

instructions are not clearly visible or
clear and hence causes confusion
among students.

SOLUTON

Well displayed instructions and work

processes written clearly and stuck on
multiple walls so that students from each
corner of the classroom can read it.
 PROJECT UPDATES/ DASHBOARDS/
WORK IN PROGRESS

PROBLEM

No visual planning board to know the tasks

that are to be performed

SOLUTION

The visual showing planning board that

Visualizes essential work tasks, and shows the
tasks that are to be done and those completed.
 REQUIREMENT OF 5 S:
SUSTAIN( SHITSUKE)

PROBLEM

Students are not aware of the 5S approach and

should be trained accordingly.

Sustain or 'Shitsuke' gives the students the

motivation to follow each rule and instruction
carefully day in and day out.

SOLUTION

Training sessions should be organised.

Regular supervision is required to ensure that
all defined standards are being implemented
and followed.
Implement improvements whenever possible.
When issues arise, identify their cause and
implement the changes necessary to avoid
recurrence.
 AWARNESS POSTERS

AWARNESS POSTERS WHICH

CAN BE INCLUDED IN GC LAB
 REFERENCE

http://www. leandeployment. com/

Visual Workplace — Visual Management, A Graphic Products Library Resource
877 . 534. 5157 Graphic Products. com. Content written by Gwendolyn Galsworth,
leading visual management authority, and adapted by Graphic Products.
Algan Tezel Lauri Koskela Patricia Tzortzopoulos , ( 2016)," Visual management in production
management: a l iterature synthesis", Journal of Manufacturing Technology Management, Vol. 27
Iss 6 pp. 766 - 799
THE VISUAL FACTORY Building Participation Through Shared Information. - Michel
Greif