Lean Production is a management philosophy aimed at eliminating waste and improving efficiency in production processes. Among the various tools used in this methodology, Visual Management plays a central role.
But what exactly is Visual Management? The goal is for anyone, even those unfamiliar with the process, to quickly gain an overview of the process, understand what is happening, and identify any discrepancies from the initial plan. In short, the person should not have to search for information; rather, the information should immediately reach the person.
In this article, we will explore the techniques that Omme Gears has implemented to support Visual Management, such as using Kanban cards for purchasing components or tools like drill bits, seals, and pins, using visual displays, and adopting a visual factory for managing oils and other equipment.
Card System: Visual Kanban for Equipment
One of the first steps Omme Gears took to implement Visual Management was the use of a Kanban card system to manage components or tools, including drill bits, inserts, seals, and pins. This system has been crucial in optimizing restocking and availability by assessing actual consumption and accounting for any stocks necessary to cover potential issues.
In the Kanban system, each card represents a specific quantity of material, placed in visible points in production to visually indicate when it is necessary to replenish or replace equipment. For example, in the case of inserts, the cards are positioned to show when stock levels fall below a certain point, automatically triggering a restock order.
Implementing this Visual Management system has allowed Omme Gears to significantly reduce lead times and material waste. The continuous availability of equipment, such as drill bits and inserts, has eliminated machine downtimes due to the lack of components, thus improving overall production efficiency.
Furthermore, visual management has facilitated communication between departments, making the status of equipment immediately visible and reducing the need for redundant verbal or written communication.
Digital Whiteboard and Visual Displays: Real-Time Monitoring and Communication
A key step in improving Omme Gears’ production performance was implementing Visual Management within the production activity planning system. Today, all of Omme’s production is managed by transferring orders onto digital post-its, which are used to determine machine loads and work sequence. Through color coding, it is also possible to get an instant overview of the production processes involved in the workflow and continuously monitor the progress at the various workstations.
Another step forward was the implementation of visual displays. These tools, positioned in strategic locations within the plant, provide real-time information on the daily and weekly workload of machines across the different production lines, enabling precise and timely organization of both operator and machine work. This eliminates time waste due to machine downtime and improves both efficiency and delivery punctuality.
This has allowed Omme Gears to improve its responsiveness to emerging problems, increasing overall productivity. Additionally, the visual displays have promoted greater employee awareness of production goals and expected performance, fostering a results-oriented work environment in line with Visual Management principles.
Visual Factory: Managing Oils and Equipment
Lastly, Omme Gears adopted the concept of Visual Management through the Visual Factory to improve the management of oils and equipment within the plant. The Visual Factory uses signage, labels, and other visual tools to organize and standardize production processes. In Omme Gears’ case, it has been especially useful for managing lubricants and work tools (discover how Omme Gears started using vegetable oil in CNC machines to reduce environmental impact)
For example, oil storage areas have been labeled with color codes indicating the type of oil and its specific use, reducing errors and improving safety. Regarding equipment, such as inserts or machine setup tools, visual indicators have been introduced to signal when equipment needs maintenance or replacement.
This Visual Management system has led to a significant reduction in downtime related to unplanned maintenance, helping to keep production lines running continuously.
Conclusion
The implementation of Visual Management at Omme Gears has resulted in several tangible improvements in management and production. The adoption of Kanban card systems for equipment like drill bits, inserts, and pins, the use of digital whiteboards, and the creation of a visual factory for managing oils and equipment have allowed the company to optimize workflow, reduce waste, and improve productivity.
Thanks to these visual tools, processes have become more transparent and understandable for everyone, promoting a more efficient, results-oriented work environment, and achieving the primary goal of Visual Management.