1. Provide real-time information on work place status by a combination of simple, effective visual information aids that allow employees to understand their influence on the organization overall performance hence allowing the employees to improve their performance.

1. Provide real-time information on work place status by a combination of simple, effective visual information aids that allow employees to understand their influence on the organization overall performance hence allowing the employees to improve their performance.

INTRODUCTION

P3 – VISUAL MANAGEMENT

1. Expose waste so that it can be eliminated and prevented from recurring making the workplace more efficient.

2. Make abnormalities in the 4Ms (Man, Machine, Material, Method) process inputs visible to everyone for prompt corrective action.

3. Enable trends in QCDMS & abnormalities to be visible for timely preventive action to be taken.

4. Motivates everybody to improve by clarifying key performance targets.

5. Makes operation standards quicker and easier to understand by all employees so they can follow them.

6. Builds participation through shared information.

7. Creates flow in the value stream and allows pull to the voice of the customer.

OBJECTIVE

P3 – VISUAL MANAGEMENT

VISUALMANAGEMENT

QualityDelivery

KPIs

METHODSMATERIAL

MACHINE

MAN

Cost

S.H.E

MAKE ABNORMALITIES & STATUS VISIBLE

9 VISUAL MANAGEMENT AREAS

P3 – VISUAL MANAGEMENT

VISUAL FACTORYVISUAL FACTORY

SAFETYSAFETY

PRODUCTIVITYPRODUCTIVITY

Associates Works ProgressProduction RateProgress Towards GoalsProduction StatusEfficient Operators

QUALITYQUALITY

Operator Prompts for Error ProofingClearly Marked Tools Reduce ErrorsVisible Calls to Support Personnel for Parts Shortage / ProblemsReduce ReworkImmediate Indication of Out of ToleranceVariables

Hazards Visual RecognitionSafe Areas Visual Display5S Eliminates Workplace ClutterAwareness of Safety Measures

P3 – VISUAL MANAGEMENT

PRINCIPLES OF VISUAL MANAGEMENT

1. Visual Control Boards. 2. Andon

3. Footprints

4. Signage 5. Obeya

4. Hansei

1. Visual Control Boards. 2. Andon

3. Footprints

4. Signage 5. Obeya

4. Hansei

VISUAL MANAGEMENT INITIATIVES

P3 – VISUAL MANAGEMENT

What is Visual Control Board

1. A color-coded , physical visual control system used for monitoring of shop-floor activities and KPIs.

Use of Visual Control Board1. Visual boards are used as activators and data communication centre. 2. The visual board area is used for shop-floor meetings.3. A centre of periodical progress reviews and updates. 4. Used to drive the business processes from the boardroom to the shop floor.

Benefits of Visual Control Board

1. It quickly gives visibility to the progress of each tasks for further action.2. Identifies the resources and activities being undertaken.

VISUAL BOARD

P3 – VISUAL MANAGEMENT

This is an example of a pull board that could be used with internal operations, as shown, or even with external customers.This is an example of a pull board that could be used with internal operations, as shown, or even with external customers.

Red zone indicates the supplier is on the verge of not satisfying their customer. Very low level of goods maintained.

Red zone indicates the supplier is on the verge of not satisfying their customer. Very low level of goods maintained.

Yellow zone indicates customer requirements are being met. Low level of finished goods maintained.

Yellow zone indicates customer requirements are being met. Low level of finished goods maintained.

Green zone indicates the customer’s needs are being fulfilled. Supplier is building more than the customer is requiring and it may be time to stop production until demand is more in line with supply.

Green zone indicates the customer’s needs are being fulfilled. Supplier is building more than the customer is requiring and it may be time to stop production until demand is more in line with supply.

The cards hanging on the hooks in the colored zones reflect the part number identified in the section, a given quantity of material in one container. When a card is on the hook it indicates an empty container.

The cards hanging on the hooks in the colored zones reflect the part number identified in the section, a given quantity of material in one container. When a card is on the hook it indicates an empty container.

Other pertinent information (e.g.. Quality performance) would be contained in the information section.

Other pertinent information (e.g.. Quality performance) would be contained in the information section.

VISUAL BOARD

P2 – VISUAL MANAGEMENT

1. Andon (Japanese for lantern) is a tool for visual management and refers to a system of signals

used to indicate the operational status (at a glance) of a machine or work center.

2. It can be used manually or automatically.

3. It also one of the principle elements of the Jidoka quality-control method.

What is Andon

ANDON

P3 – VISUAL MANAGEMENT

Use of Andon

1.Alerts management and other workers to quality or process problem.

2. Gives the worker the ability to stop production when a defect is found, and immediately call for assistance.

3. Indicates where the alert was generated, and may also provide a description of the trouble whether shortage of material or maintenance call or supervisor call.

.

ANDON

P3 – VISUAL MANAGEMENT

Defect created or foundDefect created or found

Part shortagePart shortage

Equipment/Tool malfunctionEquipment/Tool malfunction

A safety problem existsA safety problem exists

Common reasons for manual

activation of the Andon

Common reasons for manual

activation of the Andon

ANDON

P3 – VISUAL MANAGEMENT

Benefits of Andon

1. Reduces operation & maintenance costs by identifying problems before they become major issues.

2. Increases equipment availability by making downtime issues more visible, thus prompting immediate rectification to the issues.

3. Supports Jidoka implementation by making the problem status visual.

Mechanism of Andon

Andon Indicator Abnormality Response from support team

ANDON

P3 – VISUAL MANAGEMENT

Types of Andon

Coded signal lightsCoded signal lightsTextText GraphicsGraphics

Visual AndonVisual Andon

Green - no problems

Yellow - situation requires attention, production flow at risk

Red - PRODUCTION STOPPAGE: IMMEDIATE ASSISTANCE REQUIRED

1

Display production data in real time. Calculate shift efficiencies and production targets.

Ideal for STOP / WAIT / GO signaling in busy factories Boost health and safety.

Coded TonesCoded Tones

Coded TunesCoded Tunes

Prerecorded MessagesPrerecorded Messages

Buzzers / AlarmsBuzzers / Alarms

Audio AndonAudio Andon2

ANDON

P3 – VISUAL MANAGEMENT

1. Markings on the floor or work area outlining specifically where items should be placed.

Benefit

1. To ease employees during storage or retrieval.

2. It avoids employees wasting time looking for things or pondering their next move.

3. The workplace becomes clean and better organized.

4. Operation on the shop floor and office become easier and safer

5. Visible location of parts or equipment for easy traceability and save time of searching

What is Footprint

.

FOOTPRINT

P3 – VISUAL MANAGEMENT

a) Mark from the floor up to workbenches etc

b) Start with plastic tape to test out, then move to paint

1. A footprint is an outline of the items required at work areas indicating where the items should be placed.

c) Use colours to code footprints as shown in the following example, as a guideline :

Light Blue - Raw parts/material

Black - Finished good/parts

Red - Non-conforming/KIV parts/material

White - Other than parts/material

Yellow – Border of work area

2. Rules about footprints or floor borders

FOOTPRINT

P3 – VISUAL MANAGEMENT

CREATING FOOTPRINT

Yellow for work area borderYellow for work area border

SOZAILINE

KANSEI

NG VISUAL BOARDQC CORNER5S CORNER

Light blue for raw materialLight blue for raw material Black for finished partBlack for finished part

Red for non-conforming partRed for non-conforming part

White for equipmentWhite for equipment

TOOL CABINET

FOOTPRINT

P3 – VISUAL MANAGEMENT

Two types of signage

1. Displays A visual display relates information and data to employees in the area. For example, charts showing

the monthly revenues of the company or a graphic depicting a certain type of quality issue that group members should be aware of.

2. Controls A visual control is intended to actually control or guide the action of the group members. Examples of

controls are: stop signs at intersections, handicap parking signs, or no smoking signs.

Signage is any kind of graphics created to display information.

SIGNAGE

P3 – VISUAL MANAGEMENT

Signage shall be:• in accordance with international standards, code of practice• maintained • up-to-date • be well known to, and easily understood by employees, visitors and the general public as appropriate• visible from at least 1.5m and easily seen by forklift driver

Signage must be used appropriately for providing pertinent information on:• hazardous and risky areas & installation• materials• safety measures• emergency exits, etc.

SIGNAGE

P3 – VISUAL MANAGEMENT

PRO

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LIN

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LEV

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STA

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ISAT

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WAS

TE E

LIM

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ION

WAS

TE E

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ION

FLE

XIBI

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FLE

XIBI

LITY

BEST QUALITY – LOWEST COST – SHORTEST LEADTIME- BEST ENVIRONMENT & SAFETY – HIGH MORALE

BEST QUALITY – LOWEST COST – SHORTEST LEADTIME- BEST ENVIRONMENT & SAFETY – HIGH MORALE

PULL

SYS

TEM

PULL

SYS

TEM

LONG TERM BUSINESS THINKING LONG TERM BUSINESS THINKING 1

TOTAL EMPLOYEE INVOLVEMENT & DEVELOPMENTTOTAL EMPLOYEE INVOLVEMENT & DEVELOPMENT2

VISUAL MANAGEMENTVISUAL MANAGEMENT3

QU

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45 6 7 8 9

AMS 9 PRINCIPLES