Djois’ Post

Labels.... To many people quite a mundane item. But actually very important for so many reasons. Having visited Viking Signs over recent years it is hard not to be impressed with the equipment, systems and technology in use to REALLY produce quality products, small quantities or at scale! What labels do you use in your business? What safety notices and signs do you need? Lance Allcock How important is signage and labelling in your world?

Boost Your Efficiency with Single Piece Flow! 🚀 Single Piece Flow, also known as One Piece Flow, is a powerful lean manufacturing tool that focuses on moving one workpiece at a time between workstations. Here's why implementing it can be a game-changer for your production: ✅ What is Single Piece Flow? It’s a method where parts are moved through each operation one piece at a time, minimizing work-in-process (WIP). When combined with a cellular layout, this can streamline processes and reduce downtime. 🔧 What You Need for Success: 1. Consistently produce high-quality products. 2. Minimize variations in processing time. 3. Ensure equipment has high uptime and can handle takt time (rate of customer demand). 🏆 Steps to Implement Single Piece Flow: 1. Decide the products. 2. Calculate Takt Time. 3. Determine Cycle Time. 4. Check if your equipment meets Takt Time. 5. Create a lean layout. 6. Determine the number of operators needed. 7. Balance work between operators. 🎯 Benefits of Single Piece Flow: 1. Improved quality and fewer defects. 2. Higher employee morale. 3. Safer work environments. 4. Reduced space requirements. 5. Lower WIP levels. Adopt Single Piece Flow to accelerate your production, improve product quality, and reduce lead times! #LeanManufacturing #ContinuousImprovement #Efficiency

Whether you're in a manufacturing plant, warehouse, or other production environment, utilizing the concepts of “visual factory” could be your key to driving consistent efficiencies and high-quality output. Visual factory utilizes visual cues and displays to communicate important information within a production environment. This is done by implementing tools such as 5S, color-coded signs, dashboards, and floor markings that enable employees to quickly identify processes, equipment status, and workflow. By minimizing the need for verbal communication and extensive documentation, visual factories reduce confusion and errors, leading to faster decision-making and increased productivity. Having this system in place also allows for the more effective use of continuous improvement methodologies like Lean and Six Sigma. A visual factory also fosters a culture of transparency, allowing employees to easily track performance metrics and understand how their roles align to the overall workflow. I have found that employees become more engaged because they have immediate access to critical information, promoting increased collaboration and engagement on the production floor. Finally, it is a great way for a leader to take the pulse of an operation that you aren’t in everyday. When designed and deployed correctly, visual factory cues can quickly show you problems as you walk through the value stream, enabling you to take quick, targeted action to remediate. Something to think about…GK Image borrowed from https://lnkd.in/eHxmBtxJ

Breaking down complexity. 🧩 Here's a glimpse into our draft Fabrication process flow chart. By visualizing each step, we're identifying opportunities for improvement and boosting productivity. #processmanagement #efficiency #manufacturing #leanmanufacturing #kaizen #continuousimprovement

Machine safety labels in multiple language versions play a crucial role in this manufacturing customer's product assembly process. These labels, forming poke-yoke (mistake-proof) kits, ensure error-free assembly and improve their right first time. While the labels constitute a small portion of the Bill of Materials (BOM), if any are missing once the product is shipped to the end customer, it could result in significant costs to rectify. By ensuring their inclusion, the single sheet of labels is a simple solution, providing a huge amount of value. We can create many combinations of label sets to match the product variants because of our digital design & manufacturing set up.

"How often do we find ourselves fixing mistakes instead of preventing them? Error proofing, or *poka-yoke*, shifts the focus from reactive to proactive by designing processes that make errors nearly impossible or immediately detectable. 🔑 Key benefits of error proofing: 1. **Enhanced Quality:** Reduces defects and improves consistency. 2. **Cost Savings:** Fewer errors mean less rework, scrap, or recalls. 3. **Employee Empowerment:** Simplified processes reduce stress and increase productivity. Examples of error-proofing in action: ✅ Fixtures that only allow parts to be inserted correctly. ✅ Sensors that detect missing components before assembly. ✅ Visual cues or labels that guide correct actions. Error proofing isn't just about tools—it's about a mindset of building quality into every step of the process. What strategies have you used to make error proofing a part of your workflow?" **Engagement Prompt:** "Share your favorite example of error proofing in the comments! Let’s learn from each other to make our processes smarter and stronger".

Why is flow so important in Lean Production? Do you agree? #visualcontrols #leanmanufacturing #visualcommunications

The concept was originally called ‘Baka-yoke’, but Dr. Shingo changed the name to ‘poka-yoke’after realizing that the label foolproof was ‘humiliating to workers’. Like kanban and many other TPS concepts, the concept of poka-yoke has been adopted by many other industries, including software development and healthcare. Poka-yokes concepts have been introduced to the world when Shigeo Shinto wrote the book “ Zero Quality Control :source inspection , Successive Inspection and Poka Yoke”. The concept of designing the process steps in such a manner, that the mistakes become impossible (be foolproof ) , was a highly effective concept along with the concept of SMED , which he introduced in his book “ A revolution in manufacturing:The SMED system” In manufacturing, there are three main types of poka-yoke for quality assurance: 1. contact methods 2. fixed-value methods 3. motion-step methods. Each can be a control method or a warning method. Contact methods rely on sensing devices that ascertain whether a product makes contact with a device. This can be physical, as in a pin that must be placed correctly, or energy , wherein photoelectric beams sense something is not positioned correctly. Fixed-value methods are used when a process must be done a certain number of times or when a certain number of parts are associated with the completion of a task -- for example, bolts that need tightening a certain number of times or the parts required in a package. In fixed-value, a signal is given or present when the number is reached or the product is released to the next stage upon completion. Motion-step methods monitor whether a motion or step has occurred within a certain time frame or sequence. An example would be an indicator light that is turned on if a step in a machine cycle is not done in the proper sequence or time frame. Motion-step methods typically rely on sensors and devices to detect that the appropriate actions have occurred. In the indicator light example, the steps of the machine cycle are all wired to the indicator board and a timer. The light is triggered if a step has not been completed in time and in sequence.

Barcode scanning - How do you practice on the actual shop floor? The enclosed slides illustrate an internal process of barcode scanning from the end of the production stage to the finished goods warehouse: - Stage 1: Build & print out the product's label with a barcode, - Stage 2: scan for output of production, - Stage 3: scan for receiving at the warehouse, - Stage 4: Put away into locations in the warehouse, - Stage 5: Consolidate & build inventory database, - Stage 6: How to pick, tag & update the inventory, Note: If you apply for internal production processes, you can set up workstations (locations) with their IDs - employee IDs, machine IDs, workstation IDs, Subprocess IDs, plant IDs, etc. At that time, you can control the WIPs & their metrics/ KPIs suitable. {or MO#, Lot#, Serial#, Process#, Workstation#, Machine#, Mould#, Fixture#, & Jig# and BOM's part#} So, let's take time to review & study this exciting topic (Barcode scanning vs. manufacturing traceability). Hope that they are useful to you & you feel joyful with them. Thank you. #Qualityassurance; #Samplingplan; #7QCtools; #Kaizen; #Sixsigma; #QC; #Manufacturing; #Management; #Innovation #Sustainability; #CEO; #Traceability; #Safetystock; #Reorderpoint; #Warehousecontrol; #Inventoryturn;

Struggling with manufacturing inefficiencies? Automated Quality Control can help. Creaform's MetraSCAN 3D-R is here to cut down on waste, reduce rework, and boost your productivity. Discover how early issue detection and improved product quality can transform your operations. Learn more 👉 https://lnkd.in/etWu_8Vf #AQC #Manufacturing #QualityControl #Creaform