Automotive & Electronics Manufacturing
Safer, Leaner Shopfloors: Co-Designed Visual Management in Action
Challenge (Assess)
On busy shopfloors and production lines, teams struggled with cluttered tool areas, missing parts, and frequent line stoppages. Operators spent 15–25 minutes per shift searching for tools or materials. Safety compliance was inconsistent, and daily reviews were dependent on supervisors rather than systems.
We worked directly with QA leads, production teams, and operators to co-design visuals that fit daily routines:
We worked hand-in-hand with operators, supervisors, and maintenance teams to design visuals that fit their workflow:
Workspace Organization: Co-created shadow boards and labeled storage for tools and spares.
Visual Management Boards: Daily production & quality trackers designed with input from line managers.
Safety Visuals: PPE and hazard signage placed where operators themselves identified blind spots.
Compliance Boards: Simple visual audit trackers co-developed with QA teams.
Maintenance Aids: Lubrication charts, preventive check boards, and tool-condition tags.
Impact (Know Impact + Trigger Action)
Searching time cut by 70% (from ~20 mins to under 6 mins per shift).
Unplanned downtime reduced by 25–30% with clear maintenance visuals.
Audit prep effort dropped by 60%, as compliance boards kept records updated daily.
Safety behavior improved, with near 100% PPE adherence in high-risk areas.
Teams reported a stronger sense of ownership and pride, as layouts and boards were co-designed with them — “our system, our discipline.”