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A good
friend of mine: Bob Williamson, expert in these concepts defines the visual
systems as the means that allows our machines and systems "to tell us"
what they need and how well they are working.
Indeed, we all know that good communication contributes to an
organization of any size to work better. That it is exactly, the function of the
visual systems: Improve Communication!
We
should use visual systems for different purposes but always with the idea in
mind of communicating or activating the communications.
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Such is the case of the
“Opportunity Cards” seen here on the left, that we hang on the equipment or the facilities where we
indicate the need to make a repair, improvement or modification.
Also important are Information
Boards that contain graphics, the names of the participants in a project, the
reports of achieved improvements, verification lists, and many more data, are
good visual systems too. It should be
installed in the area and kept constantly up to date.
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In
this aspect of the Visual Systems we need to use a lot of creativity. It should not be regulated and
not necessarily standardized.
Let us
see some examples...
For
example in a machine, it will be convenient that in all types of instruments:
pressure gauges, thermometers, etc. to mark lines or areas that indicate the
ranges of normal operation and the ranges of risk.
Also analogical meters should be rotated them so that the pressure,
temperature or correct reading is in the position of "the 12:00"
(top). We can paint or stick color film indicating: Correct or good (green)
reading; Yellow-caution; Red-danger, either if there is risk in the operation
for the operator, the machine or that the product can be damaged or have poor
quality. In the event of digital indicators,
we should make sure to have a clear sign indicating the correct
readings. There should also exist a
clear indication of what we are measuring in that instrument.
Visual
systems should also be applied to facilitate the inspection and the maintenance.
For example, if in the verification list the point number 7 is a belts
transmission, the corresponding belt-cover will have a number 7 clearly marked.
This can be inside a square or inside a circle, this will tell us that the
number is part of a check list or report.
And
speaking of belt-covers: It is very convenient to have a clear mark that tells
us what type of belts and the number of them that are required. It is also
helpful to have an arrow that indicates the correct rotation. This is
particularly useful when a major repair is done in which it is necessary to
change or to disconnect and to reconnect a motor or electric elements. Rotation
arrows should be present in All Rotating Devices. Let us remember that there are
many machines that can suffer serious damage if they work in the wrong rotation.
Another
aspect of great advantage is that the grease fittings and points of lubrication
also be clearly identified. It is not only important to know where they are, but
what type of lubricant they should be supplied with. In many cases there may be
a color code for this purpose. With grease fittings, it is advisable to use
covers for them. Besides helping (with their color) to identify them, the covers
will avoid the contamination of bearings and lubricated surfaces.
The
same consideration for piping: standard codes exist and also conventional codes.
The important issue is that all the people, who are involved with the equipment
in its operation and maintenance, very clearly understand the code meaning. In
most of the cases we should try to have good quality quick release plugs,
which generally facilitate the maintenance operations and the tooling changes
(setups), etc. Use the color codes and also clear signs and arrows showing the
direction of flow on the pipes.
Another
practical application of visual systems is the use of pilot lights that allow
observing from the distance some problem with an equipment or system.
Also
very important among these visual systems will be the
visual board of each
machine. This serves so that at all times, any person can see the performance of
the equipment, name and if possible picture of the equipment’s operator(s) or
"proprietors", maintenance details, operation graphics, indexes of
productivity, reports and verification lists for operations of autonomous
maintenance in charge of the operator "in their own words."
Important
use of visual systems is with respect to warnings of caution and/or danger,
recommendations of use of personnel protection equipment, clean maintenance of
the area, and others that may be pertinent.
In
support of
5Ss,
an important issue is the marking of lines and location areas on the floor.
Generally, using adhesive tapes, you will be able to conserve the order and
organization of the workspace. Again, this allows all persons to understand the
correct use of the area.
There
is no limit for these visual supports. Let us make use, as it was said before,
of the creativity of the whole personnel. I have found some with very
explanatory drawings. We can even organize competitions on diverse warnings in
the plant.
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