I am happy to introduce Dr. Marco Ugarte (Gustavo Marco Ugarte Irizarri) who just received his Ph.D. from Arizona State University in the School of Sustainability. Dr. Jay Golden (from Duke) and I co-advised Marco, who did his dissertation on the environmental impact of "lean retailing" practices, like just-in-time delivery systems. Marco is continuing to work at ASU in The Sustainability Consortium. (Yes that's me on the right)

March/09/2018 - Blue Tree Hotel Manaus

Lean Manufacturing. Ji Hong from China created this idea map to introduce Lean Manufacturing to KK - a client of his that produces semiconductors. See ideamapping.ideamappingsuccess.com/ for the full story.

March/09/2018 - Blue Tree Hotel Manaus

Brady’s ToughStripe floor marking shapes, like dots, arrows and footprints, serve as additional visual communication cues within a plant. Floor marking shapes like dots and dashes require less maintenance if one shape needs to be replaced due to damage. Foot prints can help indicate where to properly stand by a machine and arrows can help with directional traffic.

Lean is the dominant industrial organisation trend.

One of its drivers is rationalization and standardization. Therefore production floors are covered with lines & signs to define what belongs where. One color for each type of use, signs to identify walkways, forklift routes, different types of work in progress…

Another driver of Lean is Change, with the so called continuous improvement. Processes are in place to review processes and eliminate wastes. In this process (kaizen…) layouts change, machines, stock, routes change place, change form… and the marking and signs need to evolve.

As they know things are bound to change regularly, the lean teams use paints, and even simple tape to mark the floors. Their system is therefore fragile and does quickly become damaged.

I found it wierd that this rational structured systematic system finished by producing chaotic yet graphic floor marks… in an ephemere forw which will disappear when the next kaizen will require a new layer of paint.

I shoot these images with a simple iPhone, without any particular caution for light… this again is an habit of lean teams which, in order to help and document their process improvement take frequent pictures of the situations (before / after change) using their company phones. The rough and sometimes blurry quality of the images is not their concern. They need to go fast to the next line, to the next kaizen.

The 5S color-coding system designates color selection for marking certain areas of a facility. As part of 5S implementation, Brady's visual workplace experts suggest using orange Toughstripe floor tape to mark QA inspection areas, as orange floor tape indicates materials or product held for inspection.

As part of the 5S color coding process, Brady's visual workplace experts recommend using ToughStripe red floor tape to mark scrap and rejects. Red floor tape signifies defects, scrap, rework and red tag areas and indicates to employees content in the marked areas is removed for a reason.

Vedzen Institute India be positive at all time.For continous improvement taking kaizen workshop with lean and six sigma tools for more details visit to vedzen.com

DTx is the authority on highly reliable embedded computing solutions. Utilizing our paperless automated Manufacturing Execution System (MES), we can offer you the absolute in traceability, quality, flexibility, and product life cycle control that no other ODM can. The interconnected MES modules (ERP, Product Control Tracking Systems – PCTS, Functional Test Automation, Product Monitoring Board, and Data-On-Demand SQL Database) document all components used and operations completed during production and provide real-time status and planning reports

To ensure adoption and workflow integration of display boards into visual management, users have the option of affixing document holders or dry erase sheets to the boards to make it easier and less time consuming for team members to update and change content.

A good kaizen activity board used for visual management should be carefully designed with readability and usability in mind, and the project methodology should actively rely on it. This implies that the use of the task board should be standardized and form part of the process, be used as a living entity and kept “healthy” and up-to-date.

Brady's visual workplace experts recommend using yellow floor marking tape to mark aisles and work areas. Visual workplace uses visual cues to guide employee behavior; yellow is a color that can imply caution, much like with traffic signals, so by using yellow floor tape, employees pay attention to the distinction between aisles and traffic areas.

Brady's IDXPERT Portable Label Printer is the ideal tool for affordable, on-the-spot labeling in data comm., electrical, material handling and industrial workplaces. The 300 dpi thermal transfer label printing creates professional-looking die-cut labels, self-laminating labels, sleeves, slide-in punch block strips and continuous tape labels. The IDXPERT Portable Label Printer is available in three versions: the keyboard layout style, the traditional handheld "ABC" style, and a "continuous only" version that only prints continuous lengths of material. Create more than 140 different high-performance labels for specific applications, including wire and cable markers, panel, rack and frame identification labels, data comm., labels, facility labels and more.

ToughStripe is a new floor marking tape created by Brady Corporation. The floor marking tape is proved to withstand forklift traffic better than other tap-based floor tape. With constant traffic demands within any manufacturing facility, the long-term adhesion and durability ensures less maintenance.

As part of the 5S workplace organization system, Brady recommends using ToughStripe’s red-and-white striped floor tape to mark areas to be kept clear for safety and compliance reasons. Red-and-white floor tape should be used in front of electrical panels, firefighting equipment and safety equipment like eyewash stations, safety showers and first aid stations.

Using Brady's ToughStripe floor signs to enforce safety and traffic rules make it easy for lean practitioners to post critical information right where it's needed on the shop floor. Floor signs create a "just-in-time" training and communication system which ensures that best practices remain clearly visible and consistently adhered to by everyone in the plant. The ToughStripe brand of products are proven to be more durable under forklift traffic, last longer because of stronger adhesion, and therefore require less maintenance.

As part of the 5S workplace organization system, Brady recommends using black-and-yellow striped floor tape to mark physical and health hazards in the workplace. The black-and-yellow striped floor tape indicates areas that may expose employees to special physical or health hazards, to indicate special caution should be used when entering and working in the area.

Use Brady’s ToughStripe corner floor marks to mark pallet storage areas. Corner floor marks are a 5S practice that indicate where items within a facility should be stored, or returned to, to maintain workflow. For areas with heavy traffic, using corner floor marks can outline a space but are less likely to be damaged by a forklift or pallet.

Safety labels are visual signs that will show employees what to do, or where to go, in case of an emergency and also identify where emergency tools are located, like fire extinguishers and other firefighting equipment.

As part of the 5S workplace organization practice, Brady's experts suggest using black-and-white striped floor tape to mark areas to be kept clear for operational reasons. Black-and-white striped floor tape indicates areas that should be kept clear for operational purposes that aren’t related to safety and compliance.

Unlike other components in visual workplace, there are no guidelines regarding the use of colors or materials, and no defined process for using a tracking board. Accepted best practices include posting in a high visibility location and clear team guidelines for its use.

Brady’s ToughStripe floor marking dashes simplify repair if tape is damaged by heavy skids. Floor marking dashes offer more structure to an work area than just corner floor marks, and are ideal for bigger spaces that need more definition.

The application of Brady’s ToughStripe floor tape can be done by one person working alone, increasing workplace efficiency. The floor tape is easy to apply in a straight line and can also be easily removed, when desired, in one long piece rather than breaking into small chunks of tape.

Create custom paint stencils on the Brady's GlobalMark 2 Color Industrial Label Printer. Brady's GlobalMark Industrial Label Maker lets users create custom paint stencils, signs, labels, pipe markers, tags and more. It has more than 290 built-in symbols, touch-and-drag editing, custom paint stencils, label previews, and a variety of other design and printing feature to help make signs and labels faster than ever before.

OSHA requires that permanent aisles and passageways must be clearly indicated and the best practice is to use floor marking tape. To help facilities comply with OSHA standards, Brady recommends black, white and yellow (or combinations of) floor marking tape be used to designate traffic or housekeeping areas.

When designing a visual management process and incorporating a visual display board, two important factors should be taken into account: The first is how to visualize work that is not directly associated with the value-added activities being performed. The second important factor is the level of granularity visualized on the board.

DoD is used to communicate and analyze scanned data from the PCTS and Functional Test Automation modules both internally and externally. This information is refreshed every 60 seconds and made available on an interactive company intranet site, as well as on production floor display stations. The collected data maps work-in-progress and completion status for all work orders and reports functional test status and assembly time.

the five whys

The Brady HandiMark Portable Label Maker helps users create indoor or outdoor custom labels whenever and wherever - throughout the plant, or even in the field. The portable label maker offers enhanced functionality and efficiency with features like auto recall, sleep mode and a clear LCD graphical display, 12 resident operating languages, alpha-numeric sequencing and PC compatibility.

Brady's MiniMark Industrial Label Printer is an affordable sign and label making solution that weighs only 4.85 pounds. This portable industrial label printer can easily attach to a PC and is ideal for creating signs, pipe markers, panel identification and more.

Brady's GlobalMark Industrial Label Maker lets users create custom signs, labels, pipe markers, tags and more. The GlobalMark make-it-yourself printer features Brady's advanced touch-screen technology, powered by a Microsoft Windows CE operating system. It can print on all of the standard sign and label materials, including Glow-in-the-Dark, static cling, magnetic, tag stock, cold temperature, reflective, polypropylene and more. The GlobalMark industrial maker has more than 290 built-in symbols, touch-and-drag editing, label previews, and a variety of other design and printing features to help create signs and labels faster than ever before.

Safety and compliance requirements changed in 2009 when the International Building Code (IBC), the International Fire Code (IFC) and the National Fire Protection Association (NFPA) 101 Life safety Code were significantly updated to include new provisions for means of egress path, or emergency exit route, safety markings and anti-slip stair

materials

Visual communications can help to avoid employee incidents, by communicating where danger could be present. Visual safety images can identify all equipment hazards by using signs or labels to indicate risk.

Visual management is the practice of using visual information techniques to manage work. For example, a six-panel communication board can be used to track key performance indicators. Ideally, the board visually represents the work that is being done by the team and acts as a “living” entity that has to be manually maintained and regularly updated.

Congratulations to the following LTLFT graduates:

(from top left)

John Peterson, Ulbrich Stainless Steels

Aman Kundra, CONNSTEP intern

David Boiano, Prospect Machine Products

Kevin Gould, Web Industries

Ted Shackford, BASF

Chris Johnson, Wood Group CRS

Bruce Lusas, Ulbrich Stainless Steels

Chris Allinson, Aerospace Alloys

(bottom row, from left)

Carmen Brickner, CLEARbrick, Inc. (trainer)

Tracey Cosgrove, Rosco Laboratories

Jan Hepola, Enterprise Minnesota

Sarah Simmons, Altra Industrial Motion

Patrick Auger, Delta Rubber Company

Create durable custom floor labels onsite and on-demand with Brady’s ToughStripe tape cartridges for Brady label printers. The cartridges for the printable labels can be used to create custom floor labels. The printable labels feature the same durability and performance as ToughStripe floor marking tape, making them an ideal solution for identifying designated storage locations and providing visual instructions on the shop floor.

For added visual impact within a facility, Brady experts suggest applying floor tape hashmarks inside the border area. Floor tape hashmarks used throughout the footprint of the marked space can help discourage the use of open space for unintended purposes.

The Brady TLS - 2200 Portable Thermal Transfer Printer offers the convenience of a portable label printer while providing advanced capabilities such as thermal transfer printing, barcoding, and multiple material configuration with barcode label storage and PC connectivity. Portable thermal transfer printers allow users to create labels in the field, whenever identification is needed.

Used to identify individual pipes within a facility, Brady offers a comprehensive collection of pipe and valve marking supplies, tools and identification systems. Clearly marked pipes let workers trace process problems and find solutions faster. Also, Brady's pipe and valve marking solutions help satisfy safety and ASME (ANSI) standards. Brady provides a wide range of pipe and valve marking solutions made of materials that match any needs; indoors, outdoors, harsh environments or light duty applications.

Our core competency in manufacturing is to provide our customers with a technology outsource alternative. DTx's proprietary Production Control and Tracking System (PCTS) can accommodate the manufacturing of the highest level assembly for our customers. The EN ISO 13485 2003 processes used in manufacturing ensure the same quality and traceability demanded in the manufacturing of your product go into every product we build. This makes DTx a natural extension of your manufacturing facility. Coupled with tightly controlled engineering change process our manufacturing core competency is to provide our customers with an identical product each time they receive it for an extended and agreed upon period of time.

PCTS utilizes online work instructions and handheld scanners to provide 100% traceability of all component part and serial numbers. PCTS also tracks employee data, order data, assembly operations, quality inspection steps, test data, intervals between scans and total build time. This data is stored in an SQL database and is included in a 2D barcode label attached to each unit. It also becomes part of the device history record which is maintained for the life of the product. Anytime a product is returned for repair or upgrade the record is updated.

Egress exit requirements now include the use of photoluminescent (glow-in-the-dark) signs. Because the material has a longer lifespan than traditional exit signs, and consume zero energy and uses ambient light to charge its glow, they require fewer building materials and less maintenance. The material can also be use in more specific locations to visually communicate a safety path, combining for a much more attractive exit sign option than the traditional LED or Tritium exit signs.

Brady's LabelMark Labeling Software is written specifically for identification applications in the telecommunication, laboratory and electrical markets where wire and cable marking is a constant and tedious job. With built-in templates, wizards, fixed text labels and free form design to simplify label making, the labeling software simplifies label making in the electrical, industrial, aerospace, laboratory, and telecomm industries.

Brady's GlobalMark Industrial Label Maker makes industrial labeling projects easier, with more than 290 built-in symbols, touch-and-drag editing, label previews, and a variety of other design and printing feature to help make signs and labels faster than ever before. The industrial label printer features Brady's advanced touch-screen technology, powered by a Microsoft Windows CE operating system, allowing users to create custom signs, labels, pipe markers, tags and more.

Brady's custom design tools are an online solution for creating unique signs, valve tags and property ID tags. Visit Brady’s custom sign shop tool and in just a matter of minutes, create a professional sign, tag or marker. The made-to-order process allows users to see the sign or tag as it's created, and select the pictograms and text that comprise each customized safety sign and tag. Select a custom header, pictogram, size, wording and more.

Lean - This was great for a photo Chase's graduation photo. His education included "lean" processes. I wanted to get this photo scrapped. I reused the clock "stamp". The quote on the red ribbon popped into my head and I looked up the author to discover it was E-LEAN-or Roosevelt. It was a sign I needed to use it. It will also look great next to my page from day 4 in my album. I love when it all comes together.

DTx utilizes a 2D and 3D bar-coding system that gathers and maintains all critical information of a product to the assembly serial number. Using a proprietary automated serial number tracking system, DTx maintains traceability of all major components within an assembly to the assembly serial number. This information is updated with each revision or repair performed on an assembly. Handheld scanners record component manufacturer’s serial number into SQL database indexed to the assembly’s top level serial number as the automated device history record. The serial numbers are recorded during the assembly process to achieve 100% traceability. Label information includes: component serial numbers, operator identification, assembly time, testing packaging, shipping, repair, and upgrade information.

Additionally, DTx is able to customize a wide variety of labels to include the material used, the text included on the label (to include 1 D, 2D & 3D bar codes), the size of the label within certain limitations, and graphics. Customized labels are not printed until needed, and the individual work instructions generated during the production process indicate which labels to apply

CBIA’S LEAN MANUFACTURING PROGRAM HELPS TWO COMPANIES SAVE NEARLY $2 MILLION

Five employees of TRUMPF Inc., in Farmington and fourteen employees of Wiremold/Legrand in West Hartford, recently completed a certificate program in Lean Manufacturing at Tunxis Community College in Farmington. This hands-on project-based program taught by a lean specialist from CONNSTEP, a consulting, training and educational resource for manufacturers, generated nearly $2 million in savings for the companies. The savings were achieved by streamlining processes and schedules, increasing productivity and eliminating waste.

The Connecticut Business & Industry Association (CBIA) established the program within the state’s community college system to train workers in lean manufacturing and supply chain management. It also provides advanced machining training using simulation and is geared toward training current and dislocated workers as well as college students.

"Together, we can help Connecticut’s manufacturers remain healthy and competitive with the highly skilled workforce needed to navigate the increasing demands of a growing global marketplace,” said Nancy Castonguay, CBIA grant manager.

CBIA administers the grant in partnership with Aerospace Components Manufacturers; the Metal Manufacturers Cluster Initiative; RENEW, Mass.; the Connecticut Community College System and its College of Technology and Regional Center for Next Generation Manufacturing; the Workforce Alliance; the Eastern Connecticut Workforce Investment Board; Capital Workforce Partners; the Workplace Inc.; the Regional Employment Board of Hamden County Inc., Mass.; the Connecticut Departments of Labor and Economic and Community Development.

The program is funded through a $1.77 million grant from the U.S. Department of Labor to help train Connecticut workers in manufacturing jobs. CBIA was one of 11 organizations in 10 states chosen to receive the advanced manufacturing job training grant as part of the President’s High Growth Job Training Initiative.