OPTIMIZATION TOOLS
Lean manufacturing
Waste of the motion
LEAN MANUFACTURING – WASTE 1 | Reducing Motion Waste
What is it?
It refers to unnecessary or excessive or non-ergonomical physical movements during the manufacturing process by worker that do not add value to the final product.
Why does it happen?
Poor ergonomic workplace layout design and inefficient workspace organization.
Operators may not be adequately trained or experienced.
Absence of 2S (Set in order).
How to identify it? ...
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Visual Factory
Andon System
OPTIMIZATION TOOLS | VISUAL FACTORY: ANDON SYSTEMS
What is an Andon System?
Andon (a Japanese word meaning "lamp") is a simple but powerful visual management tool (device) widely utilized in factories. It helps workers and supervisors know immediately when something goes wrong in production—like a machine stopping, materials shortages, or a quality problem. It uses lights, sounds, and even phone alerts to communicate these issues clearly and quickly. 🌟
How the Andon System Works?
1.- Detection & Activation.
Each production line or workstation has a small box with buttons (called an Andon box) or sensors...
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Visual Factory
Andon System
VISUAL FACTORY: FLOOR MARKING: COLOUR AND LINE WIDTH GUIDELINES✨
What Is Floor Marking in a Visual Factory?
Floor marking is a visual management technique used to organize space and improve safety, efficiency, and communication on the shop floor. Colored lines, zones, and labels guide the movement of people, materials, and equipment—making everything visible and easy to understand at a glance.
This document provides a practical guide for applying floor markings using colours and line widths.
Advantages of Floor Marking Systems
1. Enhanced Workplace Safety
Visually distinguishes hazardous zones and defines access to emergency....
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Quality Methodology
Poka-Yoke
POKA-YOKE: A SMART AND SIMPLE WAY TO PREVENT MISTAKES
What is Poka-Yoke?
It is a device or method that eliminates any possibility that the operator can make mistakes, due to fatigue or distraction, which implies defective products. Its key role is to ensure 100% verification before the process continues.
These mistakes can be, among others:
Product with Missing Part.
Product with Wrong Part Assembled.
Manufacturing Process Steps missed or incorrectly done.
Wrong Setup of Machines or Equipment.
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