Shortcuts & Tips for a Visual Workplace...5S & Visual Workplace are not the same! It is important to...

Shortcuts & Tips for a Visual Workplace

www.visualworkplaceinc.com

5S & Visual Workplace are not the same!   It is important to understand the differences

between 5S and Visual Workplace.   Both are effective tools utilized within a Lean

environment.   When applied independently, they both yield very

distinctive but remarkable results. • 5S organizes and defines the Where! • Visual Workplace defines Who, What, When

How and Why!

What is the Difference?


Many tools, one common goal…eliminate waste!   Look closely and you will see that these are all

visual tools!

Lean Manufacturing

Error Proofing

Total Productive

Maintenance

Quick Changeover

Heijunka

Standard Work Six-Sigma Kanban

Value Stream Mapping

5S

Visual Workplace


A workplace that speaks for itself and engages employees to expose problems and solve them by:

  Identifying abnormal situations   Directing behavior   Eliminating missing information

What is a Visual Workplace?


Where do you begin?   Start with 5S and organize your workplace

•  Scan to see the process. •  Sort to begin to expose waste in the process. •  Simplify to begin to define abnormal

conditions. •  Sweep to make the workplace cleaner, safer

and more productive. •  Safety to respect people.

A Road Map for a Visual Workplace


After organizing and removing unnecessary items, ask who, what, when and how.

  Create standards for each element of your workplace and eliminate missing information. •  Inventory •  Process • Work Instructions •  Scoreboards •  Territories

A Road Map for a Visual Workplace


ELIMINATE MISSING INFORMATION…

AND YOU WILL ELIMINATE WASTE!

What does missing information look like?

Missing Information


Is there too much inventory here or is it stacked too high?

Missing Information


Are your tools where they should be?

Missing Information


Where do the broom & dust pan belong?

Missing Information


What is supposed to happen here?

Missing Information


Cluttered bulletin boards with old information that are not standardized.

Missing Information


How do you find something quickly?

Missing Information


Missing Information

Is this a standard procedure?


Missing Information

Is this system obsolete? If so, why is it still displayed?


Recognizing missing information is not easy   You must teach your team to see missing

information   Start by taking a walk to specifically look for

missing information for: •  Inventory •  Process • Work Instructions •  Scoreboards

  Take photos, share them with your team and teach them what to look for in their areas

Missing Information


There are some simple methods that can be used to create effective messages.

  This visual is clearly not focused on the most important message!

  Use the following ideas and tips to teach your team how to create effective visuals and create your own benchmarks.

Visual Workplace Shortcuts



Add controls behind work instructions.



When the work instruction is missing the operator is instructed not to continue without it.



Place work instructions directly at the point of use instead of in binders.



Add work instructions to visuals identified in reverse so that you bring attention to what must be done.



When defining areas, add the instruction to the visual display.



Don’t assume they know what to do when they are done. Reminders are priceless!



Add a document directly to the visual using adhesive pouches. See www.Rochester100.com for many different sizes.



Color code inventory locations for more efficient material handling.



Color coding can increase efficiency in many areas of your facility.



Conduit and zip strips keep visuals at the same height easily instead of “S” hooks and chain for each sign.



Consider using corners to mark the floor. Less material and labor are used with corners than with striping.



Cover floor markings with clear adhesive vinyl to maintain appearance longer.



Use colored 3mm PVC for Kanban boards instead of plywood which requires painting.



Color coded flags can communicate inventory shortages without speaking.



Use powder coated sheet metal for KPI boards when you only need magnetic application. Don’t pay for applications you don’t need.



Add Min/Max requirements to inventory locations.



This pyramid sign was added to the top of this storage unit to prevent tools from being placed here instead of in their proper

location inside the cabinet.



Magnetic labels are more flexible for making location changes and last longer than adhesive labels.

Magnetic Labels Adhesive Labels



Don’t forget to add the arrows!



If you only need a dry erase board, don’t pay for a magnetic board too! We offer a dry erase board that is very inexpensive

and can be cut to size.



A 4'x8' dry erase board is $49.95 instead of $300.00.



Make your own banners and get your message noticed.



What is more effective? Avoid hand-made signs. They do not have the same impact as a professional sign.

“Your Mother don’t work here so clean up your mess! Thanx”



Professional looking visuals give your systems credibility!



Can you navigate through your facility like an airport? Customers and prospects love the attention to detail!



A PVC frame can be used to create Directory signage very inexpensively.


Conduit can also be used to create a frame. Attach signs to the frame using Velcro.



Create shadow boards for 5S cleaning supplies to reduce time spent searching.




Magnetic Labels   Buy magnet in 24” wide rolls and

cut them to size.   Thin strips pre-cut can cost more

than $10.00 per square foot.   You can save 65% cutting the

magnet yourself.


Color code whenever possible to reduce risk of error.



Beware of how high you hang your signs with respect to the size of the sign. Signs should be hung one foot off the

ground for each inch of height of the sign.

– This sign is 24” tall and should not hang any higher than 24 feet off the ground

24” high



Replace painted tool boards with custom cut adhesive vinyl for each shadow.



Create professional tool shadow with Shadow-Mark!



Detail what is required, to know what is missing.



Add an address label to the item AND the location to ensure proper placement.



Use visual scoreboards for training matrices instead of keeping them on a spreadsheet.



Gauge Mark   Create at-a-glance process controls!   It can be applied to gauges and other

inspection tools used for measuring and controlling processes.



Results of a Visual Workplace

15% Throughput 70% Material Handling 60% Space

50% Inventory 20% Machine Utilization

You Won’t Get LEAN…

Until You Get Visual!

What can you expect?

If you are interested in learning how to make your own visuals and signs, please contact us.

www.visualworkplaceinc.com 616-‐583-‐9400

[email protected]

Click for con+nuous improvement ideas.

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