Visual Management Visual Management

What is Visual Management? Visual Management is a set of techniques for creating a workplace embracing visual communication and control throughout the work environment. Visual Management

Why Visual Management ? The Vision The work environment should be immaculate, safe and self-cleaning Standards are easy to recognise and abnormal conditions are quickly identified, enabling speedy analysis & resolution. Performance and progress are readily apparent to employees. Plans are in place to significantly reduce or remove waste and defects in the process. Visual Management

How to apply Visual Management? The Tools Visual Management Tool Visual Displays To make staff aware of related data and information – charts, graphs etc Visual Controls To guide the action of staff members – sign boards, dos and don’ts signs Visual Management

Visual Display Using visual mechanisms to communicate information Visual display builds on the fourth ‘S’ (standardise) Show how to do the job (standard, agreed-upon best practice). Show how things are used. Show performance status. Identify hazardous areas Visual Management

Types of Visual Display Product and process information Area information, boundaries Standard work instructions - Standard work charts, etc Performance information - tracking against key metrics Status of current issues and improvement activities Schedules of maintenance, calibration or other support activities Visual Management

Visual Control Goes beyond simply tracking and reporting performance and any Highlights deviations that occur from the planned outcomes. Many forms of visual control exist in the Lean workplace Visual Management

Types of Visual Control Shadow boards Indicators on various items e.g. Gauges Heijunka boards – showing the status of daily schedules Design pull systems. Visual Management

Benefits of Visual Management Leads to information sharing. Facilitates worker autonomy. Supports elimination of waste. Fosters continuous improvement. Exposes abnormalities. Enables quick response & recovery. Promotes prevention. Maintains the gains. Visual Management

The Phases of Visual Management System Visual Measures Phases-3 Visual Display Phases-2 Workplace Organization Phases-1 Visual Management

Workplace Organization Objects or practices considered to be the example or model. Standards should be established by general team consensus. 5S’S Sort Stabilize Shine Standardize Sustain Visual Management

First ‘S’ - Sort Keep what is needed Eliminate what is not Identify what is out of place X - Tag Are your areas as well sorted as they should be? Keep only what is needed. Many areas have things such as tools , rags, even brooms sitting around that have not been used in months and probably never will. People are afraid to get rid of these things because they think they may be needed later. Get rid of the things that are not needed. Look for things that are not where they belong. If a tool is used for a machine in another cell isn’t that where it should be. X-tag what you don’t need, that will be discussed in a moment. Visual Management

X-Tag: X-Tagging is a way to remove things that are not needed or used anymore. Select a X-Tag leader Identify what is not needed Attach X-Tag Move to holding area Determine time to hold Move to facility holding area Tag all Safety problems Name Date Location Reason for X Tag Removal Date Visual Management

The Second ‘S’- Stabilize A place for everything and everything in its place Outlines Labels shadow boxes Designated responsibilities color coded maps X-Tag leaders Make everything easy to find, use, and return Visual Management

The Third ‘S’-Shine Cleaning is inspection Make cleaning everyday work Assign responsibilities color coded maps rotate cleaning responsibilities Utilize downtime & help others Visual Management

The Fourth ‘S’- Standardize X-Tag procedures Holding areas Cleaning procedures Location of items Operating procedures Visual Management

The Fifth ‘S’-Sustain Make it a habit It takes doing something 21 times before it becomes a habit Proper training and communication Inform all employees (especially new ones) Support and cooperation from everyone Visual Management

5S’S Sort X - Tag Keep what is needed Stabilize A place for everything Everything in its place Shine Cleaning is inspection Standardize Rules for the first 3 S’s Sustain Make it habit Cooperation Visual Management

Visual Display A method to visually communicate important information in the workplace Visual Display communicates information about: Safety Quality Operations Equipment Work Environment Progress / Achievements Visual Management

Benefits of Visual Display Makes work safer and easier Communicates information about performance Makes standards visible Makes problems recognizable Creates a shared knowledge base Visual Management

Types of Visual Display Begin implementing Visual Display with: Designated Locations : Indicate danger; Set limits; Make work easier Information Boards Work Instructions Checklists Visual Management

Tell us what, where, and how many Designated Locations : Designated Locations are the first type of Visual Display to be implemented, ex. fire safety Indicate danger Set limits Tell us what, where, and how many Visual Management

Designated Location Guidelines Determine appropriate location for all needed items Designate locations for type and correct number (quantity) of needed items Post visual indicators Create ways to recognize at-a-glance when items are out of place Visual Management

Information Board Visual Management

Information Board Guidelines Work Unit determines what will be displayed Make information easy to read and understand Always post information in same location Keep the focus clear; don’t overload info Keep information current Visual Management

Other Types of Visual Display Status Boards: Product Displays: Storyboards / Pictures Electronic Marquees Visual Management

How to implement Visual Display Identify subject to focus on Identify problems or success associated with the subject Identify the audience for visual display Choose the best location for the display Develop and test the display Improve, finalize, and implement the display Visual Management

Why do we use measurement data? To make more informed decisions about our operations To keep management and shop floor associates informed of progress To drive and fine-tune our improvement activities To educate the plant community Effective analysis requires effective reporting How we report and display data will affect how we think about it Visual Management

Company Standard Measurement Tools and Indicators Changeover Clock Production Counters Error Proof Symbols P.I. Indicator Lost Time Accidents 5 S Audit Downtime Clock Process Capability Logo Bottleneck Symbols Current Part Running Limbo Bars BOS Charts Visual Management

Visual Management Using the information provided by visuals to make informed and proper decisions or judgments daily. Visual Management

Vision The Visually Managed Factory is: A workplace that is easily understood by all. Anyone could walk into a work unit and at a ‘glance’ understand the status of that work unit, what is waste or abnormal, and where improvements are needed. If you walked into a work unit or facility on Sunday. No one is around and nothing is running. Would you be able to understand the status of that work unit? Visual Management

Status What information do we need to know? Is it? Distinguish between what is and is not normal Make waste and abnormalities obvious to everyone Constantly uncover needs for improvement Help make each persons job easier Involve everyone What information do we need to know? Is it? easily visible consistent throughout the facility or business unit current USEFUL Visual Management

Visual Management For: Workplace Safety Operations Equipment Quality Storage Visual Management

Do Our Visuals: Give you the information needed to make proper decisions? Make abnormalities and problems obvious? Promote communication and employee involvement? Make everyone's jobs easier? Recognize achievements and improvements? Visual Management

Steps Required To Implement A Visual Management System There are three basic steps: Organise the workplace using 6S Ensure that all required work standards, instruction and related information are clearly displayed in workplace Control workplace processes by exposing and stopping errors and by preventing future occurrences Visual Management

Purpose of Visual Management The purpose of Visual Management is to highlight the abnormal condition. To implement Visual Management, decide what needs to be shown, set up a trigger system to highlight it, then put standards in place for follow up action. Use world-class practices. Make everyone’s job easier Give all associates a high degree of ownership in their work, and pride in their workplace Increase communication by making information easier to understand Improve company overall success Visual Management