Visual control of power electronics manufacturing

Customer demanded intervals measured in days rather than weeks, new technology, and JIT manufacturing have all contributed to an increasingly complex manufacturing system in the power electronics industry. Leading manufacturers around the world are introducing visual controls to counteract this trend. These controls provide a place for everything and make product flow, operations standards and problems instantly identifiable. The authors describe the AT&T visual control system which uses control devices, color-coding, layouts, signs, and poka-yoke or mistake proofing devices to establish a common language throughout the workplace. This system is used to establish control, simplify assembly information at the point of use, make irregularities and nonvalue added activities obvious to both the production specialists and managers, and constantly uncover improvement opportunities. This system minimizes the time lost waiting or searching for materials, tools or documentation. It helps in the overall reduction in manufacturing cycle time. It eases the time necessary to train a new or reassigned employee. Inventories are controlled to predetermined levels by clear indicators that make it obvious if excess is present. Finally quality levels are improved since simplification, poka-yoke devices, dedicated tools and materials minimize the opportunity for mistakes. This system can be adapted to any manufacturer and has been demonstrated to be an important element of a Total Quality Management system.<>