What is a visual machine? It is equipment that speaks directly to the people that use it. It is intuitive and easy-to-understand. It is well maintained and reliable. A visual machine identifies key maintenance and safety instructions at a glance without confusion. See what a visual machine can do for you.

1. THE VISUAL
MACHINE
THE VISUAL
MACHINE
Using lean practices and visuals on equipment help improve
workplace safety, maintenance and efficiency.

2. 2,986,500Injuries & Illnesses On The Job
Sprains, strains
& tears
340,870
Back
injuries
182,270
Falls, slips
& trips
225,550
IN 2011, UNSAFE WORK ENVIRONMENTS LED TO...

3. But that’s not all. The cost of workplace injuries is also staggering:
Employer’s pay as much as
$1 BILLION
PER WEEK
in direct and indirect
worker’s compensation
costs.
Costs of an Unsafe Work Environment

4. Curb workplace accidents by labeling equipment and areas that
employers should be aware of.
Required
Labels
SOP’s
Lube
Maps
MAKING YOUR WORKPLACE & EQUIPMENT
SAFE USING VISUALS

5. THE MAIN CAUSES OF EQUIPMENT FAILURE
Improper
Lubrication
Contamination
Too little lubrication, too much
lubrication or the wrong lubrica-
tion can cause equipment failure.
Contaminated products,
processes or environments can
cause equipment failure.

6. 1 2
3
45
6
THE 6 BIG LOSSES FOR EQUIPMENT
• Obstructed
Product Flow
• Component Jams
• Misfeeds
• Delivery/Sensor
Blocked
• Cleaning
Checking
• Setup/Changeover
• Material/Operator Shortages
• Major Adjustments
• Warm-Up Time
• Rough Running
• Under Name-plate
Capacity
• Under Design
Capacity
• Equipment Wear
• Operator
Inefficiency
• Scrap
• Rework
• In-Process Damage
• In-Process Expiration
• Incorrect Assembly
• Scrap
• Rework
• In-Process Damage
• In-Process Expiration
• Incorrect Assembly
• Tooling Failures
• Unplanned Maintenance
• General Breakdowns
• Equipment Failure
SMALL STOPS
SETUP ADJUSTMENTS
REDUCED SPEED
PRODUCTION
REJECTS
STARTUP
REJECTS
BREAKDOWNS

7. RETURN ON
INVESTMENT
Reduction in
maintenance costs
Elimination of
breakdowns
10times
25-30% 70-75%
Reduction in
downtime
Increase in
production
35-45% 20-25%
PREDICTIVE MAINTENANCE
TRADITIONAL APPROACHES
MOVING FROM REACTIVE TO PREDICTIVE MAINTENANCE
Many companies engage
in reactive maintenance,
which is when you wait for
a problem to show up,
and then fix it. But this
method can be very
expensive as it results in
unplanned downtime.
Innovators are now saving
millions by using predictive
analytics and maintenance
techniques to anticipate
problems before they
occur.

8. Companies can help improve their maintenance by using
Predictive Maintenance Software.
Software like LINK360™
uses the data that
manufacturers already have available, such as:
• Equipment type
• Number of days in operation
• Operating voltage
• Planned unplanned maintenance costs
• Failure history
• Days from last/next service
• Parts analysis
...and more.
Organizing Maintenance Operation with Software

9. Early Equipment Maintenance focuses on
using previous experiences from
operators to eliminate the potential for
losses through the planning, development
and design stages.
For Early Equipment Maintenance, the goal is
to introduce a loss and defect free process so
that equipment downtime is minimal (zero
breakdowns), and maintenance costs are all
considered and optimized from the start.
MOVING FROM AUTONOMOUS MAINTENANCE
TO EARLY EQUIPMENT MAINTENANCE

10. SOURCES:
http://www.huffingtonpost.com/2012/09/11/ibm-predictive-maintenance_n_1873701.html
http://www.epa.gov/lean/environment/methods/fives.htm
http://www.bls.gov/iif/
http://www.reliableplant.com/Meta/Tags/lean%20manufacturing
http://www.industryforum.co.uk/practical-solutions/tpm/early-management/
http://www.oee.com/oee-six-big-losses.html
www.BradyID.com/visualmachine
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Preventive Maintenance E-Book