Visual Management Quick Review
Definition Visual Management is the use of controls that will enable an individual to immediately recognize the standard and any deviation from it. • Self Explaining • Self Cleaning • Self Regulating • Self Improving
Visual Management • Visual Management is used to ensure that: • There is nothing extra • The environment is immaculate, safe, and self-cleaning • Standards are easy to recognize and abnormal conditions are easier to correct • Performance and progress are readily apparent • Zero Defects is a reality! In a visually managed workplace anyone will know the who, what, where, when, why and how of an area within 5 minutes
Why Visual Management ? • Increase Safety • Enhance Quality • Reduce searching time • Increase job satisfaction • Eliminates many frustrations • Improve communication
Six Levels of Visual Management • Visual Control, • levels 3-6, prevent • defects and errors: • metrics/status board • error prevention boards • Andon lights 6. Error- Proof (defect free) 5. Prevent defects from moving on in the process. 4. Warn of abnormalities (built-in alarm). • Visual Displays, • levels 1 and 2, • share information: • signboards • demarcations • std instructions Visual Control 3. Build standards into the workplace. 2. Share standards at the site. Visual Display 1. Share information. 5S workplace organization: Sort, Store, Systematic Cleaning, Standardize, Sustain Workplace organization and standardization.
How Do We Implement Visual Management? • Start with the foundation • 5S (work place organization) • Build the second level • Visual Displays (communication) • Build the third level • Visual Controls (control the standard)
The 5S’s Are: Seiri - (Sort) Seiton - (SimplifiedStorage) Seiso - (Shine) Seketsu - (Standardize) Shitsuke - (Sustain) A Set Of Agreements Made By The Natural Work Team Concerning Work Place Organization The agreements will govern work group operations.
The Benefits Of 5S 5S provides a basis for being a world-class competitor and the foundation for a disciplined approach to the workplace. • Safer working conditions • A cleaner and more organized work area. • Quality Improvement – a standard way to do things • Reduction in non-value added time. • Effective work practices and processes. • 5S visually demonstrates that change is happening. • It’s quick, makes an immediate positive impact, and can be fun. • 5S facilitates change towards a culture of continuous improvement.
Cleanliness problem areas are identified and mess prevention actions are in place. Needed items can be retrieved in 30 seconds with minimum steps. Potential problems are identified and countermeasures documented. Proven methods for area arrangement and practices are shared and used. Root causes are eliminated and improvement actions include prevention. LEVEL 5 Continuous Improvement LEVEL 4 Focus On Reliability Proven methods for area arrangement and practices are used in the area. Cleaning schedules and responsibilities are documented and followed. Minimal needed items arranged in manner based on retrieval frequency. Work area cleaning, inspection, and supply restocking done daily. Sources, frequency of problems are noted w/ root cause & corrective action. LEVEL 3 Make It Visual Initial cleaning is done and mess sources are known and corrected. Needed items are outlined, dedicated locations are labelled in planned quantities. Visual controls and indicators are set and marked for work area. Agreements on labelling, quantities, and controls are documented. Work group is routinely checking area to maintain 5-S agreements. LEVEL 2 Focus On Basics Key area items are marked to check and required level of performance noted. Work group has documented area arrangement and controls. Necessary and un- necessary items are identified; those not needed are gone. Needed items are safely stored and organized according to usage frequency. Initial 5-S level is established and and is posted in the area. LEVEL 1 Just Beginning Work area methods are not always followed and are not documented. Needed and not needed items are mixed throughout the area. Key area items checked are not identified and are unmarked. Work area checks are randomly done and there is no 5-S measurement. Items are randomly placed throughout the workplace. Sorting Simplifying System Clean Standardize Sustaining Review: 5S Levels Of Achievement Then by Column Implementation: First by Row
Sorting Separate the necessary from the unnecessary. • Identify what is required to work a process or perform • a particular operation or task. • Remove unnecessary tools, equipment, files, binders, parts, • procedures, furniture, and other ‘stuff’ from the area. Easing access to necessary items by eliminating the unnecessary.
Simplified Storage Store It: Create a place for everything. • SIMPLFY - • Organize materials according to frequency of use. • Implement visual aids to improve communication. A place for everything and everything in place.
Shine (Systematic Cleaning) Perform daily cleaning and inspection of area and equipment to determine status and need for corrective and preventive action. • Decide how to make multiple-shift decisions. • Plan how to coordinate and communicate with other areas. • Identify key points to check to ensure proper performance. • Determine acceptable performance. • Determine corresponding visual indicators and controls. • Mark equipment and controls. • Establish ‘who and when’ cleaning plan. • Conduct daily cleaning and inspections. A process developed and used by the team.
Standardize Determining, sharing, and using the best processes and methods. • Document present work area agreement and routine checks. • Share the standard method across similar work areas. • Document new standard methods as improvements are made. • Review standardization activities, logistics, and support. Standardization serves to minimize variation and the effect of variation on quality and speed
Sustain Keeping the gains and building further progress. • Determine the 5S level of achievement. • Perform routine checks. • Analyze results of routine checks. • Measure progress and plan for continuous improvement. • Review the planned activities of sustaining. Pride in improvement, accomplishments, and the desire to do more.
A Place For Everything At a glance: “Do I have the tools and equipment to do my job?”
No Room For Chaos Organizing the work station supports standard work.
Six Levels Of The Visual Business • Visual Control, • levels 3-6, prevent • defects and errors: • metrics/status board • error prevention boards • Andon lights 6. Error- Proof (defect free) 5. Prevent defects from moving on in the process. 4. Warn of abnormalities (built-in alarm). • Visual Displays, • levels 1 and 2, • share information: • signboards • demarcations • std instructions Visual Control 3. Build standards into the workplace. 2. Share standards at the site. Visual Display 1. Share information. 5S workplace organization: Sort, Store, Systematic Cleaning, Standardize, Sustain Workplace organization and standardization.
Visual Displays • Visual displays share information and / or standards • Show how to do the job (standard, agreed-upon best practice). • Show how things are used. • Show where things are stored. • Show performance status. • Identify hazardous areas Visual Displays Communicate
Visual Controls • Visual Controls build standards into the workplace and warn, • stop or prevent abnormalities • Control inventory levels. • Indicate when people need help. • Mistake-proof the operation. Visual Controls Control
stop sign A: Passively shares information by indicating or telling. alarm clock B: Sends information by first catching attention. speed bump C: Sends information and limits responses. different-size mail slots, etc D: Ensures the right thing will happen. Types Of Visual Displays and Controls Examples :
Visual Management Quick Review