The H2 plant excels at providing visual directions, signage, and management practices. During the tour we observed several examples of applying the 5S methodology. Color coded indicators for walkways, supplies; tools and equipment are utilized throughout the facility. One example is the pipe systems being labeled to indicate content. The following color coding is used:
• Compressed air – Blue
• Water – Green
• Natural Gas – Yellow
A second example of visual management is the usage of verification stations. Key information such as “Safety Man” diagrams and “Station Work Manuals” are located at each station. Updated charts are used to visually depict progress towards achieving goals for that area and any recent issues that have occurred and need resolution or escalation. Line workers and supervisors and empowered by this process to discuss these issues in order to determine root-cause and resolution.
In addition, both manual and automated Kanban processes are in place to prevent delays from out-of-stock parts or supplies. Smaller cells close to the receiving dock use daily manual replenishment of parts. These are identified by workers tasked with viewing the level of remaining parts and replenishing them from the nearby stock. Larger parts and supplies located further away from the dock use an electronic tracking system that monitors the supply level and sends and automatic notification requesting replenishment when predetermined levels are reached
Lastly, cost, safety, quality, responsiveness, and people are evaluated and results are visually evident by area, department, and plant. We observed that the plant is not on target fo ...