VISUAL MANAGEMENT

PROJECT INCLUDES:

• Lean Manufacturing

IMEG was hired by an industry leading manufacturer of pumps to create a visual management system with the purpose of organizing flow and achieving one day to ship for a new value stream model.

THE PROBLEM

  • New challenges presented by changing the value stream model with an optimized plant layout
  • Keeping multiple pump orders together through the paint and pack processes
  • How to schedule assembly builds for common and custom pumps
  • Combining the mixed 80/20% value stream orders without long wait times
  • Split value streams for the 80/20% of volume dividing flow through the system
  • Lacking any current visual management systems for order tracking or inventory monitoring through the system

process flow

process flow

THE PLAN

  • Use the improved layout created by IMEG to evaluate new flow paths
  • Identify all current state problems which can be resolved using visual management
  • Research the latest visual management solutions
  • Gather & propose all necessary equipment and supplies required for implementation

lean

THE RESULTS

  • Delivered a holistic visual management system to ensure organization of flow for both value streams within the system
  • Provided detailed documentation on how the visual management system will work in tandem with the process plans of the new value stream to create the one day to ship scenario, including sections defining:
  • Roles and responsibilities
  • Kanban system
  • Order tracking
  • Inventory monitoring
  • Floor marking
  • 6S methodology

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