99_QS_15 Minute Lesson_VM_VC Overview 22 Pgs

Visual ManagementQuick Review

Employ Improvement Intiatives

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What Comes to Mind When You See This?


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DefinitionVisual Management is the use of controls that will enable an individual to immediately recognize the standard and any deviation from it.Self ExplainingSelf CleaningSelf RegulatingSelf Improving


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Visual ManagementVisual Management is used to ensure that:

There is nothing extraThe environment is immaculate, safe, and self-cleaningStandards are easy to recognize and abnormal conditions are easier to correctPerformance and progress are readily apparentZero 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


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Why Visual Management ?Increase Safety Enhance Quality Reduce searching timeIncrease job satisfactionEliminates many frustrationsImprove communication


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Six Levels of Visual ManagementVisual ControlVisual Display1. Share information.2. Share standards at the site.3. Build standards into the workplace.4. Warn of abnormalities (built-in alarm).5. Prevent defectsfrom moving onin the process.6.Error-Proof(defect free)5S workplace organization:Sort, Store, Systematic Cleaning, Standardize, SustainWorkplaceorganizationandstandardization.Visual Displays,levels 1 and 2,share information: signboards demarcations std instructionsVisual Control,levels 3-6, preventdefects and errors: metrics/status board error prevention boards Andon lights


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How Do We Implement Visual Management?Start with the foundation 5S (work place organization)

Build the second levelVisual Displays (communication)

Build the third level Visual Controls (control the standard)


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The 5Ss Are:Seiri - (Sort)Seiton - (Simplified Storage)Seiso - (Shine)Seketsu - (Standardize)Shitsuke - (Sustain)A Set Of Agreements Made By The Natural Work TeamConcerning Work Place OrganizationThe agreements will govern work group operations.


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The Benefits Of 5S 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. Its quick, makes an immediate positive impact, and can be fun. 5S facilitates change towards a culture of continuous improvement.5S provides a basis for being a world-class competitor andthe foundation for a disciplined approach to the workplace.


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Review: 5S Levels Of AchievementImplementation: First by RowThenbyColumn


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SortingSeparate 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.


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Simplified StorageStore 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.


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Shine (Systematic Cleaning)Perform daily cleaning and inspection of areaand equipment to determine status and needfor corrective and preventive action.A process developed and used by the team. 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.


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StandardizeDetermining, sharing, and using the bestprocesses and methods.Standardization serves to minimize variation and the effect of variation on quality and speed 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.


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SustainKeeping the gains and building further progress.Pride in improvement, accomplishments, and the desire to do more. 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.


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A Place For EverythingAt a glance: Do I have the tools and equipment to do my job?


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No Room For ChaosOrganizing the work station supports standard work.


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Six Levels Of The Visual BusinessVisual ControlVisual Display1. Share information.2. Share standards at the site.3. Build standards into the workplace.4. Warn of abnormalities (built-in alarm).5. Prevent defectsfrom moving onin the process.6.Error-Proof(defect free)5S workplace organization:Sort, Store, Systematic Cleaning, Standardize, SustainWorkplaceorganizationandstandardization.Visual Displays,levels 1 and 2,share information: signboards demarcations std instructionsVisual Control,levels 3-6, preventdefects and errors: metrics/status board error prevention boards Andon lights


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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


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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


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Types Of Visual Displays and ControlsExamples :


Visual ManagementQuick Review


Module name: Visual Management latest author: Jay WatsonDelivery Time: 15 min.Employ Improvement IntiativesExercise Have the class work in their table groups to answer the following questions:What is your first impression of this picture?Can you tell what is going on in this picture?3. Do you think this has any impact on this persons productivity?

This is an Engineering Work Station.Engineering requirements and documents come through this station.It is very difficult if not impossible to know where a document is at any point in time.Documents 3-4 months old were found in the piles.No real time quality feedback to collect data and measure the processNo standard work - if the person operating this station is absent it would be very difficult to determine where to start.Employ Improvement IntiativesExplain what visual management is reference the picture on the last page

Employ Improvement IntiativesCover this slideKey emphasis the 5 Minute rule in the takeaway at the bottom

Employ Improvement IntiativesAsk the team why they think we should have a visual management system draw these ideas out cover what they do not bring up in discussion

The Visual Business can help you in many ways:Increase safety in your workplace by warning about safety hazards, communicating safety standards, and eliminating obstacles and unsafe conditions in the workplace.Enhance Quality (reducing defects) by mistake-proofing.Reduce the amount of time you spend searching for supplies, tools, equipment, people, or information.Eliminate many frustrations, such as those caused by not having the supplies, equipment, or information you need where you need it and when you need it.Improve communication between yourself and your coworkers by standardizing certain types of communication mechanisms (check- sheets, status boards, signs, and labels), by creating a common understanding about how operations should be performed, and by providing necessary information in a usable form at point of use.Increase job satisfaction by producing all the results listed above, and revitalizing the workplace through worker participation.Employ Improvement IntiativesGo through this slide

A big part of stability is knowing what you have and knowing when there is a problem; Visual Control makes this possible.You should begin 5-S before much else; if a layout change in in the works, you do not want to move things that are not needed.That would be waste!And, you would not want to create the proper place for everything and then accomplish the move/re-layout.Employ Improvement IntiativesRefer back to the pyramid ask how they think these elements should be implemented start with the foundation firstEmploy Improvement IntiativesAsk the team if they know what 5S is, do they know what the 5 Ss are? Go through what each S is on a flip chart more detail on each one later in the module

IMPORTANT NOTE:There are several translations from the original Japanese 5SsNo matter the translation, the intent is the same. The original words were not arbitrarily chosen. The English translations are less precise and dont really matter all that much.The SPIRIT of each S is very important.The implication in these words is that you pass from one level to the next -- that you cant be effective with a later S without achieving high levels of success at the lower level of S. You can demonstrate this on the 5-S table.Employ Improvement IntiativesInclude these points in the discussion from a 5S videoEmploy Improvement IntiativesGo through this slide with the class

The table, radar chart, and instructional pages for sort and storeare review from the baseline module. Cover these quickly; review the key points and focus more on the remaining material. None of the photos contained herein are duplicates; show and discuss each of these.This is a simple, yet effective, map for evaluating and measuring improvement with 5-S implementation.Look at level 5 for simplifying. Everything can be retrieved within 30 seconds. Think about what this means, and what would have to be done to get there. This is a quick way to identify monuments within the process and the barriers to flow.Before any re-layout is done on any project, sorting level 2 should be attained. No need to move unnecessary items, which will also clutter the new process.Wait until the re-layout has been completed before simplification work and systematic cleaning plan. Create the process, then create a place for everything (and for systemic cleaning, everything in its place).

Employ Improvement IntiativesExplain the first S

Ask the class for examples; you may get workplace and home examples.

Employ Improvement IntiativesThis S is sometimes called simplify or storeEmphasis: be organized. Know what is needed, know what you have, and where it is.Eliminate wasteful searching. This can eliminate a major source of frustration for people.It has been found that up to 30% of a persons job can be spent looking for the parts, tools, data, etc to do their work.The steps of preparation and simplifying activities were covered in the 5-S portion of the baseline module.Employ Improvement IntiativesThis implies that a plan is created and executed by the work area team.Cleaning tasks (which restore the intended state) might need to be done on differing frequencies, depending on the specific need. For example, tools might be returned to their proper place every four hours, and the floor swept every hour (say, in a cutting process) or once a day.Look carefully at the floor, aisles and around the machines.

How much oil, dirt, dust and metal shavings can you find? Are any parts of the machine dirty with oil or metal fragments? Are any air, electrical supply lines, or pipes oily, dirty or in need of repair? Are oil outlets or ventilation grids clogged with dirt? Are light bulbs, reflectors or shades dirty?

Ask for thoughts on Administrative examples.The cooling vent on a PC is a common example.

Employ Improvement Intiatives5-S should become daily habit.

Assign responsibilities to apply these procedures. The standard for 5-S should be established and agreed upon by the people who work in the process.

Integrate 5-S activities into the regular work activities. Ask the team: Do you have standards, procedures, and assigned responsibilities for Sort, Storage, and Shine?Employ Improvement IntiativesEmploy Improvement IntiativesShadowing all the tools so if something is missing everyone knows what tool it isvery visual!!Ask the class what else is lean in this photo.The tool cart is on wheels; it can easily be taken to the place of work and removed when it is not needed.The place to return a tool is obvious - this saves time and encourages sustaining.At a glance, one could tell if all of the needed items are available.

This factory example might be the best descriptor of this notion for implementation outside of the factory.Employ Improvement IntiativesEach work station here is identical with standard tool holders, colored bins, (blue is Vendor Managed Inventory, yellow is work in-process). Each station labeled the same way.Employ Improvement IntiativesA big part of stability is knowing what you have and knowing when there is a problem; Visual Control makes this possible.You should begin 5-S before much else; if a layout change in in the works, you do not want to move things that are not needed.That would be waste!And, you would not want to create the proper place for everything and then accomplish the move/re-layout.Employ Improvement IntiativesCover the specifics of visual displays and visual controls (next two slides) on a flip chart.ie lights / bells on a RR crossing

Employ Improvement Intiativesie crossing arms dropping on a RR crossingEmploy Improvement IntiativesRun through examples Employ Improvement IntiativesEmploy Improvement Intiatives

99_QS_15 Minute Lesson_VM_VC Overview 22 Pgs

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