Visual factory

Anyone who has been involved in the implementation of lean understands the concept and importance of visual methods of communication, which are often referred to as visual factory methods. Visuals make knowledge that previously resided with individuals and in computer systems public knowledge. Visual communication methods include signage, charts, signaling cards and containers, lights, and process maps. All of these methods support the lean goal of employee engagement in continual improvement. Let s briefly explore each of these to understand their relevance to lean safety. 

The last visual factory tool discussed in this chapter is process mapping. 

Visual factory Use safety visuals to engage employee base in daily safety activities. 

Another safety topic could be a review of safety metrics. The number of days since the last accident or incident could be a topic. Or consider combining a lean visual factory tool with the team s safety metric. During the flash meeting, have someone on the team affix a green cross safety sticker onto a monthly calendar each morning, for the previous day, if there were no injuries or incidents. A sample calendar that could be used with individuals was shown in Chapter 4, Figure 4.3. Starting each and every day with safety first topics raises safety awareness. 

Visual factory A lean methodology used to disseminate operational information to everyone using visual means or methods. If implemented effectively it can eliminate the need for conversations and computergenerated reports and make needed information public or accessible to everyone. 

As little as three factors can confront the investigator with an intractable situation if he chooses to proceed classically. One way out is to use the factorial approach, which can just be visualized for three factors. An example from process optimization work will illustrate the concept. Assume that temperature, the excess concentration of a reagent, and the pH have been iden-... 

Visual stimuli may influence the perceived odor intensity. An odorous and an odorless solution that were slightly tinted with yellow were more often considered odorous than the corresponding clear solutions with and without odor (Engen, 1972). Based on these findings, Cain (1978) pointed out that in the realm of air pollution the sight of black smoke from a factory may drastically increase the number of odor complaints whether or not the odor is indeed more intense. 

In the late 1950s the subtle and serious consequences of methyl mercury exposure became evident in Minamata, Japan. Initially, early signs of uncoordinated movement and numbness around the lips and extremities, followed by constriction in visual fields in fishermen and their families, baffled health experts. Developmental effects were clearly evident in infants who exhibited subtle to severe disabilities. This spectrum of adverse effects was finally related to methyl mercury exposure from consumption of contaminated fish. Minamata Bay was contaminated with mercury and methyl mercury from a factory manufacturing the chemical acetaldehyde. Mercury was used in the manufacturing process, which also resulted in both mercury and methyl mercury being discharged into Minamata Bay. The fish in the bay accu-... 

Factorial design, analytical methods, 624 Fast Blue B, Upid peroxidation visualization, 670... 

Saini and Sharma [30] reported a series of 145 chemical eye injuries in 102 patients treated at a major referral center in India between 1984 and 1991 [30]. Bilateral injuries were seen in 42.1% of patients. Acids and alkalis accounted for 80% of chemical ocular injuries in this series. Two-thirds of the injuries occurred in young people working in laboratories and factories. Roper-Hall Grade III and IV injuries were seen in 52 eyes (35.9%). In total, 102 eyes (70.3%) recovered with a visual acuity of 6/60 or better. Ten eyes (6.9%) had no light perception. Phthis bulbi (a deformed eyeball with no light perception) occurred in 71.4% of the seven deliberate chemical assault victims but in only 3.6% of the accidental ocular chemical exposures. The final visual acuity was better in the eyes with less severe grades of chemical injuries on presentation [30],... 

Figure 11 Visual representation of a two level full factorial 2 design...

Figure 6.21. Visualization of an optimal 2J / fractional factorial design. The circles indicate factor combinations used in the experiments. It can be seen that this choice of experiments will span the...

The visual appearance of a commercial sugar product has long been used as an index of the impurities contained. Despite a general advancement in instrumentation, determination of the perceptual color is still frequently the primary control in the manufacture of white or near-colorless sugar products. This situation is shared by cane-sugar refineries and beet-sugar factories a similar state of affairs exists in the production... 

Appropriate designs might be based on factorial designs (full or fractional) or a central composite design. Response surface methods frequently rely on visualization of the data for interpretation. 

The visual, aesthetic component of his bold plans was central. Clean, smooth lines were something he associated with the all-business leanness of the machine. He was positively lyrical about the beauty of the machine and its products. And houses, cities, and agrovilles could also "emerge properly equipped, glitteringly new, from the factory, from the workshop, faultless products of smoothly humming machines. ... 

Prior to harvest or viral infection, visually inspect the multiplate cell factory for any signs of contamination and/or leaks. 

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