The Visually Instructive Workplace

What does it mean to have a
visually instructive workplace?

Needed information is easily seen and available at
the location where it is needed.

Equipment Labels: All equipment, valves, switches and machinery should be clearly identified and labeled. Information on the labels should be complete, accurate and understandable. For example, if a coal feeder is designated as CCF2-05, don't label it with just this number. Completely identify it as "Crushed Coal Feeder CCF2-05".

Process Flow Labeling: Mark all tubing, pipes and conduits to identify their function and the direction of flow. Use signs to identify the areas in your plant in which each step of the process takes place.

For example, the coal feeder area might be identified as: "Furnace #2 Crushed Coal Feeders". The pipe bringing coal into the feeder would be identified as: "From Coal Bin 2-05". And the outlet pipe from the coal feeder would be labeled, "To Coal Pulverizer 2-05".

Although this is a very simple example, it demonstrates that anyone could stand by the crushed coal feeders and know exactly where they are and what is happening in the process,

Tubing, pipes and conduit should be marked at frequent intervals such that they can be identified (the markings are visible) from any reasonable location in your facility.

Instrument Labels: All instruments should be identified with labels. An identifying number, as well as their function in the process should be identified. Bar codes might also be used for quick, automatic identification. However, don't rely on bar codes alone. People must be able to look at the label and be able to identify the instrument without the aid of a bar code reader.

Directional Signs (Emergency Evacuation): Make it easy for people to get around in your facility and find the areas they need to get to. Don't assume that, because everyone has worked there for a long time, you don't need directional signs. In particular, emergency evacuation signs are critical as people, who need to get out of the building quickly, may be distracted, confused or disoriented during an emergency.

Safety Signs / Hazard Warnings: Use large, clear signs and labels to identify hazardous materials, areas and safety concerns. Identify who can and who can not enter certain areas. Identify what must be done before entering certain areas. Provide first aid information, emergency phone numbers and emergency proceedures.

Don't forget about maintenance. After a few years signs and labels may become dirty and unreadable. Have a regular, frequent inspection and maintenance schedule. Clean dirty signs and labels. Replace missing and damaged signs and labels. Remove or update out-of-date signs and labels.

Note: Having your own sign / label maker helps ensure signs and labels are properly maintained or replaced, in a timely manner.

Lockout / Tagging: In addition to using lockout tags, use permanent signs to provide lockout information, lockout proceedures and safety reminders.

Operating Proceedures: Be sure plant personnel have the information they need to operate your equipment and machinery. Post start-up proceedures, shut-down information, process information and safety information directly on the equipment. That way they'll always have the information they need for the correct, safe operation of the equipment and machinery.

Maintainance Information: Post maintenance proceedures and schedules on equipment and machinery. Be specific about what should be done. For example, if oil levels need to be checked weekly, don't post a sign that says, "Check Oil Levels Weekly". Be specific about what should be done and when it should be done. The sign should say, "Check oil level Mondays at 8:00 am".

Storage Information / Warehouse Labeling: Most warehouse managers are well aware of the importance of proper labeling and signage. However, don't forget about storage areas outside of the warehouse or tool room. Any location that is used for storage, whether temporary or permanent, should be identified as such. Use signs to present a description of the materials, tools or equipment that may be stored at that location. Display the rules that apply to that storage area -- such as "NO FLAMABLE MATERIALS" or "NO OVERNIGHT STORAGE".

The bottom line is: The best approach is to have the information people need, at the point where they need it. This eliminates wasted time caused by someone having to return to their office or shop to look up the information they need. It helps prevent mistakes, by having the correct information readily available at the point of need. It helps keep your facility organized, saving time and increasing productivity. And it helps keep your employees safe and healthy.