MRO Today - A plant that talks

A plant that talks
Improve safety and productivity by creating a Visually Instructive Plant

by Rod Anderson

Workplace changes over the last few years have forced companies to take a new look at the way they communicate with employees. The workforce is aging, and companies are expected to produce more with fewer employees. Also, information technology advancements have made the work environment more complex.

As companies look for ways to improve communication, increase productivity, streamline processes and improve safety, they begin to realize the benefits of a well-labeled facility, or as Brady Worldwide calls it, a Visually Instructive Plant (VIP).

What is a VIP?
A recent electric power industry study found that 54 percent of workplace errors occur as a result of inadequate or missing labels.

By having consistent, clear, visible and comprehensible markings, employers can reduce costly errors and mistakes as well as reduce the risk of accidents and injuries. Through a VIP program, companies also reduce maintenance costs and training time – all leading to increased profitability.

A Visually Instructive Plant takes an organized approach to marking. It has written marking procedures in place and standards applied to every label/sign in every area of the plant. All things are marked clearly and consistently, providing an efficient standardization from work area to work area, and from plant to plant. Labels contain as much information as necessary to actually "communicate" with employees – and the information is right where it’s needed.

A clean start
Getting organized is the first step to becoming a VIP. The Japanese 5-S methodology offers a systematic approach to creating a clean, uncluttered work environment. The VIP program adds a sixth S (smart workplace) to the original five of sort, shine, set in order, standardize and sustain.

Information where it’s needed
Part 2 in the VIP process involves implementation of a comprehensive facility identification program to assure your facility is as safe and productive as possible:

• Following the 6-S process, identify the marking needs for your facility, or a specific work area within the plant.

• Determine what to label; what information to include on labels; what label materials perform best in specific work environments; what the labels should look like, etc.

• Install signage throughout the facility, including pipe marking, electrical marking, valve and equipment marking, tank and vessel marking, safety marking and more.

• Finally, develop and implement written procedures with regard to facility marking and ongoing maintenance.

Of course, marking needs vary from company to company. Some may choose to implement the VIP program themselves. For those companies, Brady offers a comprehensive manual providing step-by-step instructions on how to evaluate existing signage, create and implement written marking procedures, record and track a program’s effectiveness, and make VIP an ongoing process. The manual also includes up-to-date info on OSHA regulations regarding safety and facility identification.

Using the VIP manual as a guide, companies can start marking by utilizing ready-to-go identification products and user-friendly sign, label and tag-making software and equipment.

Others companies may choose full turnkey VIP support, including project management, facility assessment, plant marking specifications, marker installation and written follow-up procedures.

Moltech Power Systems (formerly Energizer Power Systems) used the support approach to complete a site survey. The survey helped the company implement a VIP program that improved efficiency and reduced maintenance costs.

"We have piping running everywhere throughout our plant," says Billy Shannon, a facilities drafter responsible for labeling at Moltech’s Gainesville, Fla., site. "The labeling has really helped our employees. It used to take someone 20 or 30 minutes to trace down a line. Now with proper labeling in place, it takes about five minutes. It’s definitely made us more efficient and productive."

Markings such as signs, labels and tags make everything in your plant, from equipment to processes, more user-friendly. And, by putting important information at the point of need, you can quickly increase the knowledge of your employees, eliminate confusion, and reduce the potential for operator errors and accidents. Fewer errors leads to less wasted product, reduced equipment downtime and greater overall productivity.

Rod Anderson is Identification Services Group manager for Brady Worldwide, Inc., a supplier of safety and facility identification products. To learn more about the VIP program, visit http://www.bradycorp.com. For general information, call 800-817-8080, or visit www.bradycorp.com.