How to Use Lean for Visual Factory Design

Our team specialises in developing fully bespoke Lean factory layouts that help manufacturing companies to maximise safety, efficiency, output and employee engagement whilst reducing costs, delays and waste. The designing of a Lean and Visual Factory requires multiple considerations, which we’ve outlined below to help you better understand the process involved.

Lean and Visual Factory design

If you’re looking for expert consultation and meticulous delivery, make sure to explore our Lean manufacturing factory fit out service. We’ve helped countless businesses across multiple sectors to accelerate output and achieve world-class status through outstanding Lean layouts. Whether it’s a new-build facility or the transformation of an existing manufacturing plant, we always follow the three Ds of visual design:

Decide: We begin by visiting your factory to carry out an assessment. Our visual management experts will discuss your vision and determine what’s currently preventing it from coming to fruition. Once we have a clear picture of where you want to be, we apply our Lean consulting and visual design expertise to decide what needs to be done to facilitate a Lean, visual and safe work environment.
Design: Working with you and your design team, we then create an initial plan that explains which changes will be made and how they will benefit day-to-day operations. This virtual representation is highly detailed and gives a genuine feel for how your factory will function and perform once the upgrades have been carried out. This is complemented by a roadmap that lays out how your vision will be transformed from virtual designs to physical reality.
Delivery: The final stage is implementing these changes through our comprehensive fit-out service, which includes designing, supplying and installing all of the visual assets required for your factory to run at optimum efficiency.

Workshops in Lean layout

Whilst we’re always here to design and implement Lean principles throughout your facility, the key is to equip your team members with the knowledge required to sustain top levels of efficiency and safety. Our Lean Layout workshop gives you the tools to make this happen, as it will help your teams to understand all of the elements involved in maintaining peak performance within a Lean and Visual Factory.

Knowledgeable and engaged employees are the ultimate resource, as they play a core role in enhancing how a business operates on every level. From reducing costs and improving product quality to reducing waste and minimising your carbon footprint, we’ll show you how to embed continuous improvement throughout your company culture.

MPM safety barriers

A major factor in manufacturing environments is movement, as people, vehicles and goods are constantly moving from one place to the next. This creates potential hazards to employees, fixtures and stock, which is where MPM safety barriers prove an exceptional investment.

Whilst most barriers are made from metal, the MPM range is manufactured from a strong polymer that doesn’t rust and instantly flexes upon collision This allows it to quickly return to its original shape rather than forming dents, which ensures fully functional barriers that last far longer than the traditional type. More importantly, as a result of absorbing the impact, the kinetic energy is not transferred to the vehicle operator, effectively preventing injury and creating a safer work environment.

Projected floor markings

A new offering that we’re particularly excited about is the Alis Tech projected floor marking system. Whilst traditional floor markings become faded, scuffed and obscured in very little time, projected floor markings eliminate operational blindness and near-misses because they remain highly visible no matter what. Any symbol or warning can be projected directly onto the floor as either a blinking, pulsing or non-stop visual message, allowing you to tailor the system to your unique and ever-changing needs.

As well as increasing safety through visual communication, projected floor markings can be updated, changed and relocated whenever required. This removes the lengthy process of taking up old floor markings and replacing them with new versions, as well as eradicating the risk of essential floor signage not being present even for an instant. Needless to say, this also comes with a very positive impact on your bottom line.

Tools for visual communication

We then of course have the classics of Lean and visual management, which Clarity has been providing to businesses since day one. Below are a few of our most popular visual management assets that support Lean through improved communication, safety, accountability and sustainability:

Visual management boards: The key to effective visual management boards is that they should be simple, up to date, precise, actionable and, of course, visual. As a result, the 1-3-10 rule is always in effect.

Shadow boards: Essential to 5S and SMED, shadow boards are a simple yet powerful way to save time, improve health and safety standards and promote pride in the workplace. When every tool is accounted for, production and maintenance are unstoppable.

Cleaning stations: Hygiene and tidiness are at the heart of smooth operations. By supplying your departments with bespoke cleaning stations, all equipment is easily accessible at all times.

5S cuboids: A relatively new addition, 5S cuboids create a focal point for multiple visual management boards, plus they can even incorporate a shadow board for tools and cleaning equipment. Playing a vital role in keeping 5S under control, these rigid, compact, mobile and fully customisable cuboids are also the perfect display area for our magnetic overlays.

The 7 rewards of visual management

If you’ve read this far, you probably already know why visual management is so important when it comes to designing factories, production lines and manufacturing environments. However, to fully understand the many benefits that our consultancy, design and fit out services will bring to your company, make sure to read our blog on The 7 Rewards of Visual Management.

Ask us about Lean and Visual Factory layout

Ready to take your production, safety, efficiency and profitability to the next level? Get in touch with our team on +44 (0)1482 296451 or fill in our contact form and ask us about our Lean and Visual Factory fit out service.

How to Use Lean for Visual Factory Design