PRINCIPLE 3 – visual management

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PRINCIPLE 3 visual management
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P3 VISUAL MANAGEMENT
INTRODUCTION

• 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.

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P3 VISUAL MANAGEMENT
OBJECTIVE

• 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.

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P3 VISUAL MANAGEMENT
9 VISUAL MANAGEMENT AREAS
S.H.E
MAKE ABNORMALITIES STATUS VISIBLE
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P3 VISUAL MANAGEMENT
PRINCIPLES OF VISUAL MANAGEMENT
Hazards Visual Recognition Safe Areas Visual
Display 5S Eliminates Workplace Clutter Awareness
of Safety Measures
SAFETY
S
VISUAL FACTORY
Associates Works Progress Production
Rate Progress Towards Goals Production
Status Efficient Operators
PRODUCTIVITY
P
Operator Prompts for Error Proofing Clearly
Marked Tools Reduce Errors Visible Calls to
Support Personnel for Parts Shortage /
Problems Reduce Rework Immediate Indication of
Out of Tolerance Variables
QUALITY
Q
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P3 VISUAL MANAGEMENT
VISUAL MANAGEMENT INITIATIVES

• Visual Control Boards.
• Andon
• Footprints
• Signage
• Obeya
• Hansei

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P3 VISUAL MANAGEMENT
VISUAL BOARD
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 Board
• 1. 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.

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P2 VISUAL MANAGEMENT
VISUAL BOARD
Red zone indicates the supplier is on the verge
of not satisfying their customer. Very low level
of goods maintained.
Other pertinent information (e.g.. Quality
performance) would be contained in the
information section.
Yellow zone indicates customer requirements are
being met. Low level of finished goods
maintained.
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.
Green zone indicates the customers 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.

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

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P3 VISUAL MANAGEMENT
ANDON
What is Andon

• 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.

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P3 VISUAL MANAGEMENT
ANDON

• 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.
• .

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P3 VISUAL MANAGEMENT
ANDON
Defect created or found
Common reasons for manual activation of the Andon
Part shortage
Equipment/Tool malfunction
A safety problem exists
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P3 VISUAL MANAGEMENT
ANDON
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
Response from support team
Andon Indicator
Abnormality
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P3 VISUAL MANAGEMENT
ANDON
Types of Andon
Visual Andon
1
Graphics
Text
Coded signal lights
Green - no problems

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

Yellow - situation requires attention, production
flow at risk

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

Red - PRODUCTION STOPPAGE IMMEDIATE ASSISTANCE
REQUIRED
2
Audio Andon
Coded Tones
Coded Tunes
Prerecorded Messages
Buzzers / Alarms
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P3 VISUAL MANAGEMENT
FOOTPRINT
What is Footprint

• 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

• .

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P3 VISUAL MANAGEMENT
FOOTPRINT
CREATING FOOTPRINT
1. A footprint is an outline of the items
required at work areas indicating where the items
should be placed.
2. Rules about footprints or floor borders
a) Mark from the floor up to workbenches etc
b) Start with plastic tape to test out, then move
to paint

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
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P3 VISUAL MANAGEMENT
FOOTPRINT
Black for finished part
Light blue for raw material
Yellow for work area border
SOZAI
LINE
KANSEI
NG
VISUAL BOARD
QC CORNER
5S CORNER
TOOL CABINET
Red for non-conforming part
White for equipment
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P3 VISUAL MANAGEMENT
SIGNAGE
Signage is any kind of graphics created to
display information.
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.

Figure 8.0
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P3 VISUAL MANAGEMENT
SIGNAGE

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

• 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

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BEST QUALITY LOWEST COST SHORTEST LEADTIME -
BEST ENVIRONMENT SAFETY HIGH MORALE
AMS 9 PRINCIPLES
PRODUCTION LEVELLING
STANDARDISATION
WASTE ELIMINATION
FLEXIBILITY
PULL SYSTEM
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