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VISUAL CONTROLS - Mieruka

Presented By:Jude Abreo (81)

Ketan Mokal (82)

Mridu Sharma (83)

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VISUAL CONTROL

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Contents

Introduction1

Visual Control – An Understanding2

Advantages And Limitations3

Conclusion4

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Introduction

Basic Philosophy

1. Visual elements in a workplace have a tremendous impact on education, morale, and productivity.

2. A visually dynamic workplace energizes employees, builds pride and ownership, and conveys the strength and currency of the organization.

3. Design and graphics, art and color, sculpture and dimension– all have profound effects.

4. Far from simply “prettying up the office,” they create an environment of visual stimuli that convey goals and expectations, that foster a collaborative attitude, and most important, that cannot be ignored!

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Introduction

What is Visual control ?

“ One picture is worth a thousand words ”

Visual control are means, devices, or mechanisms that were designed to manage or control our operations (processes) so as to meet the following purposes:1. Make the problems, abnormalities, or deviation from standards visible to everyone

and thus corrective action can be taken immediately (Identification).2. Display the operating or progress status in a easy to see format (Informative).3. Provide instruction (Instructional).4. Helps formulate and proliferate plans (Planning).

Thus all visual control devices can be classified as one of ‘3I1P’. (Three I’s and 1 p)

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Visual Control – An Understanding

Identification: Helps you know what something is.

Forms Seen: Labels and stickers.

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Visual Control – An Understanding

Informative: Gives important information in an area to update status or situation.

Forms Seen: Information walls, charts, informative sheets and diagrams.

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Visual Control – An Understanding

Instructional: Tells you how a task is to be performed.

Forms Seen: Work instructions, floor markings and signs.

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Visual Control – An Understanding

Planning: Helps formulate the plan and let others know what the plan is.

Forms Seen: Gantt charts and white board walls.

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Visual Control – An Understanding

Prerequisites1. Management must believe in openness and transparency.

2. Employees have the ability to observe critically and share their feelings.

3. Regular follow – up at all levels about problems, facts and figures being shared

Implementation costs Expenses required are relatively low (expenses for Andons, visual digital displays,

etc.)

Implementation time1. Visual controls are extremely easy to implement after 5S program initiation.

2. The 4th S (Standardization) and Visual Control go hand in hand.

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Visual Control – An Understanding

Applicability / AdaptabilityVisual Control is applicable to services, software and even in offices.

Training NeedsLow training requirements; information is simplified and can be understood by any one be it top management or line operators.

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Visual Control – An Understanding

Examples of visual controls: Visual Control Board

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VISUAL CONTROL

Visual Control – An Understanding

Examples of visual controls: Shadow Board

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Visual Control – An Understanding

Examples of visual controls: Inventory Control

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VISUAL CONTROL

Visual Control – An Understanding

Examples of visual controls: Level Scales

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VISUAL CONTROL

Visual Control – An Understanding

Examples of visual controls: Visual Workstation

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Work Instructions

Information Board

T P M Checklist

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Visual Control – An Understanding

Examples of visual controls: Color Codes

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Visual Control – An Understanding

Examples of visual controls: Andon Displays

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Visual Control – An Understanding

Examples of visual controls: What is Andon ?

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• Jidoka or ‘Automation with Touch’ is implemented in the Toyota Production System.

• Machines automatically stop production as soon as an error is detected.

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Visual Control – An Understanding

Examples of visual controls: What is Andon ?

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• As machines had the capability to automatically stop production a single operator may visually monitor multiple machines.

• Toyota plants pioneered the use of a display board system to highlight a problem on the line; this is an Andon board.

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Advantages and Limitations

Advantages:1. Information is easily and quickly understood.2. Corrective and Preventive actions take lesser time.3. Increases awareness of supervisory and control personnel.4. Transparency in working.5. Attacks lead time, easy inventory management and simplifies line

monitoring.6. It infuses a sense of pride and self – confidence.

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Advantages and Limitations

Limitations:1. People tend to hide the facts if something goes wrong.2. Detailed information is difficult to display.3. Improperly designed visual displays may lead to a breakdown in

communication4. Improperly designed displays may also be a distraction.

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Conclusion

The Essence

1. Workplace is able to “speak” with the help of visual displays.

2. If practiced systematically, will help implementation of JIT, TQM and SCM

Requirements

1. High levels of Motivation

2. Management’s willingness to openly display information

The Role

1. Speeds up non – verbal communication

2. Opens up new avenues for improvement and moral boosting.

3. Makes work safer and easier.

Limitations

1. Require properly designed displays

2. High levels of detail are difficult to portray.

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Questions ?