GROUP ASSIGNMENT

MEM673 WORLD CLASS MANUFACTURING

KAIZEN AT VISUAL WORKPLACE INC.

GROUP MEMBERS:

1. AMIRUL AZLI BIN AHMAD ZAHIDIN // 2014479498

2. MUHAMMAD FIKRI BIN ABDUL RAHIM // 2014876074
3. MUHAMMAD FAZLY BIN RAMLY // 2014628066
4. MUHAMMAD ARIFF BIN MUSTAMIN // 2014827516

GROUP : EM220 8D8

LECTURER : DR NOR HAFIEZ MOHAMAD NOR

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Introduction of Visual Lean Manufacturing

Visual lean manufacturing known as kaizen or continuous improvement uses a variety of

tools to eliminate unseen waste the foundation of all these tools is a visual system. It is a strategy
where employees work together proactively to achieve regular, incremental improvements in the
manufacturing process. In a visual workplace, visual devices are positioned at the point of use,
giving employees instant access to the critical information they need, right when they need it.
Visuals can easily be understood at a glance, eliminating the wasted downtime that had
previously been spent searching, asking, or waiting for information. This model can greatly
improve your productivity, cost, quality, on-time delivery, inventory and equipment reliability.

In assessing these areas, employers might consider implementing 5S which is one of the
core principles of 5S is visual order, making it a natural tool for developing a visual factory. 5S is
a Japanese lean methodology designed to reduce waste and optimize productivity through better
workplace organization. The five pillars of the 5S are Sort (Seiri), Set in Order (Seiton), Shine
(Seiso), Standardize (Seiketsu), and Sustain (Shitsuke). In 5S, visual devices like red tags, floor
marking tapes, and shelf labels are used to ensure that there is a place for everything - and
everything remains in its place after a kaizen event is over. Likewise, the Standardize and Sustain
steps of 5S are virtually impossible to manage without the use of visuals such as check sheets,
schedules and audits.

Visual workplace Inc. is a company that provides those tools in the form of a complete
system that includes software and hardware that allows manufacturing companies and their
employees to create an inexpensive high-impact visuals in house by using mobile in-house sign
shop. The Sign Shop is an affordable tool that provides the easiest, most cost-effective way to get
the signs and visuals you need for a safer, leaner, more efficient facility. From the moment you
recognize a need, you can have signs and visuals when you need them, where you need them, at
a fraction of the cost. The employees can create work instructions, dry erase boards, tool shadow
board, magnetic labels, floor graphics, directional signs, safety signs and hundreds of other
visual controls at a moments notice as new ideas arise and very little cost. The system creates a
no size limitations from the very small to the exceptionally large.

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Product of Visual Workplace Inc.
a. Dry Erase Boards

Magnetic Dry Erase Board Overlays are printed with your graphics on a thin, durable acrylic
film with a magnetic frame that attaches to your dry erase board. It is different from conventional
hand-made graphics board. These overlays can be used on your existing magnetic dry erase
boards with saving you time and money.

b. Tool Shadow Boards

Tool shadow boards is a custom tool shadow boards placed directly at the point of use. The
benefit of this board is it can quickly identify missing items and sustain workplace organizations.
It can create your own tool shadow boards using Shadow-Mark and pegboard. It more durable
and looks professional.

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 c. Floor Marking Tape

Reflective Floor Tape provides high visibility to increase safety. Dont overlook the need to
illustrate the importance of noticing an object or when it should be avoided. With many color
options available, reflective floor tapes are essential to create a safe work environment. Excellent
for fleet and vehicle markings, poles, columns, buildings and fences to provide bounce-back
reflectivity and material handling equipment.

d. Lean and Safety Signs

The purpose of Lean and safety sign is to transform your facility into a lean, productive
and safe workplace. Communicate standards, maintain continuous improvements and sustain
lean operations with pre-made, ready-to-ship signs. It also can be use for 5S Signs to promote
and reinforce your training. Red Tag signs help identify unnecessary items in your workplace.
Many companies have their own definitions for workplace organization.

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Visual Workplace involvement in online business

Visual Workplace worked with thousand visual factory throughout United States, Canada
and Mexico. Visual Workplace have new online support business which giving access to
thousands of best practice lean templates, manual downloads, software downloads, training
webinars, training videos and technical support. All of them can be customize or use them just
the way are. Their websites is mobileinhousesignshop.com.

The beauty of Visual Workplace not only they have sign making crew, they also learn
about 5s. It helps them to communicate well to their clients and make them understand when
providing business. They also have 500 templates and those templates relate to lean
improvement. As example, if the clients need tool board, scheduling board or simple sign of trash
pit, the Visual Workplace websites provides templates that can help them and dont have to
customized designer as well can pick the templates easily.

The key to implementing lean manufacturing is creating effective visual environment.

The clear visual helps the staff to recognize and organize the workplace control processes,
identify hazard and communicate standards all with the ability to maintain and grow the system
they created. The lean facilitator, Christine Jones said that the crew can be teaching, have a lot of
information, experience and them sharing it each other. It helps them do the next step making
their place much better.

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The results when implementing the right tools to improve:

70% decrease in material handling

60 % decrease in space

50 % decrease in inventory

20 % increase in machine utilization

20 % increase in productivity