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Taking a Tour of the Visual Factory

DFF is no stranger to efficiency. Our team of experts provides assistance through design for manufacturing (DFM), design for assembly (DFA) and geometric dimensioning and tolerance (GD&T) enhancements, allowing us to specialize in medium-to-high volume production of precision machined components and electromechanical assembly services. Despite our expertise, recent successes have led to unprecedented growth which, in turn, required a brand new streamlined and intelligent process. In this blog, we’ll give you a tour of our new visual factory to explain how it ensures we always provide our clients with a Defect Free Flow.

What is the Visual Factory?

The cornerstone of the visual factory is the digital Fusion GEMBA Board—designed by Datanomix—providing a real-time, automated indicator of safety, quality, delivery, cost and inventory (SQDCI). The board measures development at both strategic and tactical levels—tracking order progress, current performance and our ability to hit both quality and delivery targets with consistency. Simply put, the board serves as the pulse of the factory, retrieving and sorting vital information to provide an overview of the operation. We installed a dozen large TV screens around the production area and office suites so that everyone can see clear production indicators in real-time.

To supplement the board, the visual factory also consists of a clean and organized shop and quality assurance (QA) floor, visual instruction manuals for employees and the use of CAD drawings for concept design work. All of these elements add up to a living, breathing factory that’s consistently improving upon methods and practices to ensure on-time delivery, efficiency and supply availability.

Change Spurred by Growth

Prior to the visual factory, our production managers would walk the factory floor and work alongside operators to correct problems and make the necessary changes to improve production speed and accuracy. Rapid growth and demand from new, global customers made this process unsustainable.

As the necessity for our services increased, we quickly hired hundreds of new employees, deployed additional multi-million dollar robotic machine cells and increased our total square footage to 300,000. Now, with our new Fusion GEMBA technology, each and every square foot of space is planned and documented to serve a purpose for our customers.

Visualizing Success

DFF is a partner you can trust to go above and beyond for on-time delivery, efficiency and supply availability. Contact us today to learn more about our visual factory and the ways it can assist with your precision machining and electromechanical assembly needs.

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