Visual Management - Production Scheduling Board

[Hugo Gon?alves]

Hi all,

Following the Lean approach I'm trying to establish in my section, I'm trying to create a production scheduling board, on which I can monitor instantly dates of production, product location in process (product is a 10 by 6 meters power transformer) status (operation, delays, problems) and personell involved. Kind of a Gantt with extra informations (perhaps with dates/process axis). Does anyone have some examples or suggestions on how to establish the best way to present the info?


Regards,

 

[errhine]

We have 2 methods of doing this. We have poster charts on the floor with status and problems and we use a computer database (Filemaker Pro) that all of the office staff can veiw with the some of the same (and more detailed) information.

 

[sspoldir]

One awesome way is instead of replicating the data into a computer program... setup a webcam pointed at the scheduling board, that way office people (potentially even customers) can look at it and find out in real time instead of having to query a DB.

 

[S Johnson]

In "The Toyota Way", Jeffrey Liker describes a white board that Toyota uses in their distribution centers to track and manage their employees progress on that day's work. It was a simple and elegant (and cheap) solution. Of course, this is work in a DC but it may fit what you are looking for with little investment (a lot cheaper than computer programs). I do not have the book infront of me otherwise I could give you more information on this tool and how it works.

 

[Punzie]

Toyota uses "Kamishibi Boards" as visual control boards for tracking production, audits, problems etc. Though I have read it as theory I do not have any personal experience in observing/working on it.

If any member can describe it with some pics it would probably help out.

 

[gpainter]

Magnat boards work great. Be careful of control.

 

[ngkjrs]

magnet boards are good enough. If the button is red (with a face drawn as if it is crying), it means the machine is down, If the button is green (with a smiley face), it means machine is running, if the button is yellow (SMED in progress), Blue (waiting).

As far as details of production, i follow a simple excel sheet with production schedule and dates kept in a transparent folder clipped to the magnetic board.

try out and give me feedback. it works well for me! if i can get better suggestions, it is welcome.

 

[wmarhel]

Hi all,

Following the Lean approach I'm trying to establish in my section, I'm trying to create a production scheduling board, on which I can monitor instantly dates of production, product location in process (product is a 10 by 6 meters power transformer) status (operation, delays, problems) and personell involved. Kind of a Gantt with extra informations (perhaps with dates/process axis). Does anyone have some examples or suggestions on how to establish the best way to present the info?


Regards,

Just a thought, but who will be responsible for keeping this board updated? If it isn't simple and very quick to update then the board itself could become a burden to operation/workers and eventually stop being updated.

Have you looked at the process seen where you could shorten the time enough to have the product "flow" or at the very least work in a FIFO (First-In-First-Out) process? I guess I'm wondering about what value or insight you feel this board will present for the workers and yourself?

Ideally, if your running an MRP/ERP system, you should be able to extract the information from there and develop your own dashboard using barcodes and scannings.

If your using kanban cards then it is easy to set-up a board. See this post for an example of how a kanbard board might work: Animated Kanban Board.

In regards to Punzie's posting, the correct spelling is "Kamishibai" in case you do a search. It isn't really used for tracking production, but for more an auditing function. Here are a few resources regarding this visual management method:

"The Toyota Way: A Sociotechnical Learning Organization in Action" RealPlayer Presentation and Slides available for Download

and

What is Kamishibai? From the blog Gemba Panta Rei.

Wayne

 

[JBAND]

To track progress of work I have in the past used a white board on the shopfloor. List the process steps that the products go through along the top and down the side the part numbers (now this works best for runners).

Having split the board into a grid you can write work order (job) number in the box that corresponds to where the order is upto in the process this obviously needs to be updated by operator or team leaders close to the process and should not be used for very short cycles were you would end up spending more time at the board than on the job. But it can be a good way to monitor several products with multiple orders running at various stages of your process.

 

[dente]

Hi,

Good examples of visualisation on the shopfloor can be found on a dutch website : tnpvisualsolutions.nl

On this website you can even play with a visualisation creator.
You will find examples of 5S, action board, policy deployment board,
safety boards etc ...

Good luck