VISUAL FACTORY

(Tick the appropriate answer. No overwriting. Each question carries 1 mark. No negative
marks for wrong answers.)
Questions:
1. The purpose of Visual Factory is _________.
a) It makes problems more visible for early rectification.
b) To impart information visually at the time and place it is needed.
c) Self-explaining, Self-regulating, Self-ordering & Self-improving workplace
d) All of the above
2. Benefits of having a visual workplace?
a) Self-explaining, ,
b) Self-ordering
c) Self-improving
d) Self-regulating
e) All the above
3. Which one of the following is not true of Visual Factory
a)
b)
c)
d)
e)

Its a combination of signs, charts and other visual representations of information.

quick dissemination of data within a lean production unit.
attempts to reduce the time and resources
communicates waste to team verbally or in written form or audits.
Reduces product and process variations.

4. Which chapter of saksham closely linked with Visual factory provides lists, specifications,
look and feel & vendor details?
a) Crewload chart
b) Plant & Facility
c) Labour Collection Analysis
d) 5S
5. Which is not a part of Visual factory OI?
a) Visual performance management
b) Factory floor marking & signages
c) Shadow boards
d) Andon
e) Crew load chart
6. Match in the department/person responsible against each work
S.No

Description

Selection of Area team leads for

VF implementation
responsible for implementation
and sustenance of Visual Factory

Department/Person
Responsible
Visual Factory
Mentor
Visual factory
mentor

3
4
5
6
7

audit their segment once for

every month for sustenance
Audit reports review
de-facto Visual Factory mentor
Training and certification of VF
Ensure only the current ship-set
documents / data is stored in the
shop-floor / office areas

Program Manager
Area Team leads
Saksham
HOD Prod
Area Team leads

7. Are visual blockages allowed inside the factory shopfloor

a) No
b) Yes and can be anywhere
c) Yes but not near the aisle ways
8. Which of the following is not an area of focus of visual factory?
a) Visual Performance Management
b) Elimination of Visual Obstructions
c) Factory Floor Markings
d) Color coding & Visual control
e) Labour collection analysis
9.

10.

11.

12.

13.

14.

A person should be able to see from wall-to-wall when walking the factory floor at all times
is a part of 5S?
a) Yes
b) No
c) Cannot say
No solid walls, boards, or other opaque items in shop floor ensure easy detection of issues?
a) Yes
b) No
c) Cannot Say
All the opaque storage structure on shop floor (Work benches, Material handling Equipment,
Platforms, Tool trolleys, MSP trolleys, Almirahs, Consumable racks, dust bins for hazardous
materials etc.,) should be of less than 10 feet height.
a) Yes
b) No
c) Cannot Say
All jigs should be only less than 5 ft height mandatorily?
a) Yes
b) No
c) Cannot Say
It is preferable to use transparent materials like glass & Acrylic material instead of opaque
materials like Wood or Metal across the floor. Notice boards, AOS racks, Almirah doors
should be prepared from such transparent materials.
a) Yes
b) No
c) Cannot Say
The Rooms (or) Office blocks on the Shop floor must be completely Visual (Transparent
work area) unless the work content demands for opacity?
a) Yes

15.

16.

17.

18.

19.

20.

21.

22.

23.

b) No
c) Cannot Say
All unavoidable opaque monuments or areas which require opacity (e.g. closed opaque LPI /
NDT rooms, or completely closed Opaque office blocks) must be placed at one end of the
shop?
a) Yes
b) No
c) Cannot Say
Each work area /work center must have a robust set of consistent performance metrics in easy
viewing through SQCT/Performance management Boards?
a) Yes
b) No
c) Cannot Say
charts/metrics must be complex & visually confusing such that only process specialists should
be able to understand the performance of an area by looking?
a) Yes
b) No
c) Cannot Say
SQCT boards must be made from opaque materials like wood/metals to ensure no visual
blockages?
a) Yes
b) No
c) Cannot Say
Andon system is a
a) simple and consistent visual production status indicator
b) flag pole indicating NVA
c) indicator showing status of a line at a glance with system generated report
d) to bring immediate attention to problems as they occur in the manufacturing process
e) All the above
f) None of the above
Factory Floor Markings has a clearly marked location with outline and description for
everything
a) Yes
b) No
c) Cannot Say
No part/material/tool/ is ever out of location unless in use
a) Yes
b) No
c) Cannot Say
The purpose of floor marking is to indicate the exact position & to identify at a glance the
designated storage locations for materials, product, tools & equipment.
a) Yes
b) No
c) Cannot Say
Choose the Right Match
Option

Colour of tape
/ paint

Option

Location

Blue

Aisles (Aisle width needs to

be min 4 feet)

a)
b)
c)
d)
e)

Red

Green

White

Fluorescent
yellow

Yellow and
black

Used as cell separators

All items inside the cell:
Jigs, Work benches, Material
handling Equipment,
Platforms, Tool trolleys,
MSP trolleys, Almirahs,
Document Storage Area
Hazardous materials: Fire
extinguishers, Emergency
Exits, Consumable racks,
dust bins for hazardous
materials
First aid equipment,
Emergency eye wash areas,
Helmet stands
Electrical panels, pipes on
floor, Moving & energized
machines, Trenches.
Dashed or Zebra mark
indicate caution

A-1, B-2, C-3, D-4, E-5, F-6

A-2, B-4, C-5, D-3, E-1, F-6
A-3, B-1, C-2, D-4, E-6, F-5
A-6, B-5, C-4, D-3, E-2, F-1
None of the above

24. Which of the following data does the Visual factory OI does not provide
a) Supplier Name & Contact No
b) Approximate Price per Unit
c) Frequency of Use
d) Sizes reqd
e) Places to use
f) None of the above
25. Factory signage helps one easily understand who, what, when, where, why, how of an area
and allow even a layman to adequately navigate the factory.
a) Yes
b) No
c) Cannot Say
26. Which of the following is not an example of Visual Factory signage?
a) cabin name plates
b) conference rooms names
c) safety board
d) Emergency exit board
e) FOD poster
f) None of the above

27. Match the following

Option

Description

S.No

CABIN NAME
PLATES

Safety Board

Emergency exit
board

Fire
Extinguisher

First Aid

Emergency
Assembly point

FOD poster

General Safety /
PPE Awareness
posters

a)
b)
c)
d)
e)

A-3, B-5, C-1, D-8, E-2, F-7, G-6, H-4

A-2, B-4, C-5, D-3, E-1, F-6, G-8, H-7
A-3, B-1, C-2, D-4, E-6, F-5, H-7, G-8
A-6, B-5, C-4, D-3, E-2, F-1, H-7, G-8
None of the above

Picture

28. Locations where part/tool outlines are used to visually identify what belongs where and
highlights when something is missing is not shadow boards.
a) Yes
b) No
c) Cannot Say
29. The use of tool shadow boards provides an immediate visual aid that will increase
productivity and improve overall workspace organization.
a) Yes
b) No
c) Cannot Say
30. Shadow Board should ideally be of dual colour tone e.g. black foam on top and a lighter
colour (e.g. light blue) on the background. This ensures that any missing item is noticed
easily. (Visually Control)
a) Yes
b) No
c) Cannot Say
31. Shadow boards are applicable to
a) Detail parts only
b) Tools only
c) NDTs & Jigs details only
d) Both A & B only
e) All the above
f) None of the above
32. Use of photos in the work area to visually demonstrate the correct method of working is
called as
a) Visual performance management
b) Visual boards
c) Visual work instructions
d) None of the above.
33. Who provides visual work instructions
a) Tooling team
b) Manufacturing Engineering
c) Production
d) Quality
34. Different types of fasteners should be colour coded and specifications of the colours must be
clearly identified.
a) Yes
b) No
c) Cannot Say
35. For installing a rivet, Locating, Drilling, Sealant application, Rivet installation all of these
operations should be shown separately with pictures attached.
a) Yes
b) No
c) Cannot Say
36. Color coding is an easy way to separate different items and to visually determine if something
is misplaced / mis-located. Colour coding may also be used to specific things like red for
danger / emergency
a) Yes
b) No
c) Cannot Say

37. Yellow colour is used for railing & other caution areas for the same
a) Yes
b) No
c) Cannot Say
38. The colour black or black paint must not be used for any of the assets in the shop floor
a) Yes
b) No
c) Cannot Say
39. The width, qty and location of the tool storage rack is determined by the number of

hand tools used in the work area.

a) Yes
b) No
c) Cannot Say
40. Use of Wooden steps is allowed as per Visual factory OI?
a) Yes
b) No
c) Cannot Say

41. Storage bins not required for items like C- clamps, clecos etc. within the cell?
a) Yes
b) No
c) Cannot Say

42. Which of the following definite space must be available within the cell with proper
indications?
a) Storage for Removable tools
b) Storage for Small Tools like NDTs etc
c) Storage for Semi Finished Goods
d) Scrap yard
43. Which of the following OIs along with VF OI also check for Visual Factory Adherence?
a) 5S
b) Crew load chart
c) Both A & B
d) None of the above
44. Procurement of any storage items, boards & assets must be approved by the mentor for
acceptance to visual factory norms prior to procurement?
a) Yes
b) No
c) Cannot Say
45. Regularly scheduled maintenance walks for the purpose of sustenance of Visual Factory
should be done by
a) Visual Factory Mentor only
b) Any Management personnel only
c) Saksham team personnel only
d) Program Manager only
e) All the above
f) None of the above
46. Quarterly leadership factory walks through the production areas, into the deep corners,
behind tools and external areas of the factory designed to demonstrate support to sustenance
of Visual Factory is done by

a) Visual Factory Mentor only

b) Management personnel only
c) Saksham team personnel only
d) Program Manager only
e) All the above
f) None of the above
47. Any observations during these Gemba walks must be recorded and tracked to closure by
a) Program Manager
b) Visual Factory Mentor
c) Area team leads
d) Both A & B only
e) All the above
48. Leadership Support to Visual Factory & Leadership Gemba Walks are conducted by
a) Program Manager only
b) Head Operations
c) Both A & B
d) None of the above
49. Implementation & sustenance of Visual Factory is responsibility of
a)
b)
c)
d)

Program Manager only

Visual factory Mentor
Both A & B
None of the above
50. Visual Factory Audit is done by
a)
b)
c)
d)
e)

Program Manager only

Visual factory Mentor
Saksham Team only
Both A & B
None of the above