© Lean & Mean Consulting. All rights reserved. 2015

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Visual Management Visual Controls Visual Displays Visual Metrics

World-Class Standards of Operational Excellence

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Learning Objectives

1. Appreciate how Visual Management supports the Zero Injury Safety Culture

2. Understand that Visual Management is an integral part of the Continuous Improvement transformation

3. Become familiar with common visual tools such as Andon, Red Tagging, MOS boards, Kanban, error-proofing, standard work, OEE boards, etc.

4. Gain knowledge on how to apply visual tools to add structure and stability to operations, reducing variation and increasing efficiency

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Introduction

5S - The foundation for a visual workplace

Types of visual management

Visual display

Visual metrics

Visual control

Contents

Common visual tools

Activity Boards

MOS, OEE,

Hourly attainment

Standard work

Kanban

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Visual Controls / Visual Metrics / Visual Displays

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What is Visual Management

Visual Management enhances the smooth flow of information by using visual and audio signals instead of texts or other written instructions

Visual Management is the concept of making a workplace safe and more effective by making the current condition of a workplace obvious at a glance

Visual Management includes a set of techniques that makes operation standards visible so that people can follow them more easily

These techniques expose waste so that it can be prevented and eliminated

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The name given to a whole range of activities for communicating and controlling what needs to be done.

What is this?

Fundamentals of Gemba House Visual Management Visual Management

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Fundamentals of Gemba House Visual Management

Visual Management allows us to:

• See abnormal conditions as soon as they occur.

• Tell at a glance how we are doing.

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• Safety & Health Information

• Identification of people, places and objects

• Procedures and methods of work

• Quality standards, instructions, results

• Status visibility

• Problem visibility

• Scheduling • Communication

Types of Visual Management

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Visual Controls

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EVERYDAY

VISUAL CONTROLS

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5 Disciplines for a Successful Visual Management System

Disciplines Description

Project identification

• Define implementation areas and establish current conditions and baselines

Workplace organization • Implement 6S as a strong foundation

Visual display

• Create a visual communication system providing the right information in the right format at the point of need

Visual metrics

• Quantify the path to targets for success

Visual control • Create an error-proofed environment to promote easy adherence to standards

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5S workplace organization can be enhanced by the use of visual tools

Visual tools help you to monitor results and look for things easily and quickly

Creating a Visual Workplace

Note: Visual management IS NOT decoration !

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3 Types of Visual Management

• Label to make it perfectly clear where things belong and what the procedures are

• Shadow boards, boundary samples Visual Display

• Quantify the path to targets for success

• OEE Boards, MOS Boards, Attainment Boards

Visual Metrics

• Create an error-proofed environment to promote easy adherence to standards

• Poke Yoke, Red Rabbits Visual Controls

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Visual Displays

Make it clear when something is out of place or missing

Labeling is mandatory to make it obvious where things belong

Labels are for everyone: those working in the area, those that are new to the area, and those that might need to know things about the area.

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Examples of Visual Display

Floor markings

Bin labels for different components

Scheduling

Labels to identify documentation locations

Temporary work station or activity

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Andon refers to any visual display that shows status information

Andon is the Japanese word for paper lantern

Serves as warning system to signal and identify problems in the process

What is an Andon?

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Andon Examples

4 Function andon system

Warning sensors linked to andon and/or audio device

Andon escalation process

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Visual Metrics

Allow everyone to “know the score” and they make out-of-standard situations immediately obvious

Enables everyone to ‘see’ how we’re performing

Helps highlight problems, or variances from standard

Encourages employee involvement and open discussions

Facilitates the communication and identification of areas that need improvement

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• Gaps? Trends? What is happening?

• Root causes? Why?

• Correct the problem – implement containment action?

• Prevent the problem – permanent corrective action?

What needs to be done?

• Who does what? • Any support needed?

Who is going to do it?

• Prioritization? • Deadline? • Milestones?

When is it going to be done?

Example of Visual Metrics

Manufacturing Operating System (MOS)

Visual Metrics provide a mechanism to take action…

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Create an error-proofed environment

Promote easy adherence to standards

Display goals and targets

Are simple devices or visual standards to help prevent mistakes

Make it easy to find things

Visual Controls

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Examples of Visual Control

E-stop Labeling of disposal bins Requirements

Lock out procedure Stop before proceeding Shadow Board

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Error-proofing refers to techniques that make it impossible to make mistakes

Also known as Poka Yoke

Error-proofing helps people and processes work right the first time

Error-proofing

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Error-Proofing Has Dual Focus

Defects Mistakes Process

Prevention Poka-Yoke that focuses here works on mistake prevention or making

mistakes impossible.

Detection Poka-Yoke that focuses here

works on mistake detection, or making sure mistakes do not turn

into defects.

People and systems do make mistakes. A portion of mistakes turn into defects.

Visual Controls / Visual Metrics / Visual Displays

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What is an Activity Board?

Activity board is a visual tool to guide teams to action

It is a visual scorecard for the team’s progress toward company, departmental and team visions and targets

It keeps everyone’s attention on the project, using colors and graphs to make information clear to everyone who sees it

Is a focal point for team meetings, and a place for management’s feedback and encouragement

Key TPM Tools

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MOS Board OEE Board

Post the applicable schedule at each activity board so it is clear:

• when the meetings occur • who needs to be present • what information will be reviewed

Examples of Activity Boards

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Example of Hourly Attainment Board

HOURLY ATTAINMENT BOARD Line X

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Visual management is an essential part of a Lean management system

Visual management uses displays, metrics and controls to help establish and maintain continuous flow

Visual tools reinforce standards, and help people detect abnormalities at a glance

For visual management be effective and sustainable, it has to be integrated and align with management standard work - MOS, OEE, BP – the way we manage the business

Summary

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