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Visual Management

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Visual Management

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Visual Management is a business management technique that communicates important information in the physical workplace. It is a system of information displays, visual controls, labels and signs, color coding and other markings instead of written instructions.

Visual Management is a business management technique that communicates important information in the physical workplace. It is a system of information displays, visual controls, labels and signs, color coding and other markings instead of written instructions.

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Visual Management

  1. 1. www.citoolkit.com Continuous Improvement Toolkit Visual Management
  2. 2. www.citoolkit.com Visual Management 2 The Continuous Improvement Map Multivariate Brainstorming IDEF0 Document control Check Sheets** Flowcharting Flow Process Charts** KPIs SCAMPER*** Pugh Matrix Lateral Thinking Reliability Service Blueprints Affinity Diagrams Mind Mapping* Attribute Analysis Morphological Analysis How-How Diagram*** Control Charts Waste Analysis** Time Value Map** Value Stream Mapping** Value Analysis** Suggestion Systems Histograms Activity Networks RACI Matrix Stakeholder Analysis Improvement Roadmaps DMAIC SWOT Analysis Policy Deployment Project Charter PDCA Gantt Charts MOST PERT/CPM Daily Planning Delphi Method Payoff Matrix Relations Mapping Data Mining Just in Time Automation Product Family Matrix Flow Spaghetti** Multi-vari Studies Decision Tree FMEA PDPC RAID Log* Fault Tree Analysis Paired Comparison Traffic Light Assessment TPN Analysis Risk Analysis* Run Charts Scatter Plots A3 Thinking Importance Urgency Matrix Four Field Matrix Critical-to X Portfolio Matrix Force Field Analysis Decision Balance Sheet Break-even Analysis Voting Quality Function Deployment Pick Chart Gap Analysis* Bottleneck Analysis Cost Benefit Analysis Kaizen Events Control Planning Standard Work Mistake Proofing Quick Changeover Visual Management Simulation TPM 5S Health & Safety Best Practices Pareto Analysis 5 Whys Prioritization Matrix Hypothesis SIPOC* Matrix Diagram Fishbone Diagrams Tree Diagram* Root Cause Analysis Correlation DOE ANOVA Nonparametric Chi-Square Regression Observations Kano Lean Measures Benchmarking*** Interviews Graphical Methods Data collection planner* Questionnaires Probability Distributions MSA Descriptive Statistics Cost of Quality* Sampling Focus Groups Capability Indices Process Yield Project KPIs Normal Distribution Data Collection Understanding Performance** Implementing Solutions*** Planning & Project Management* Managing Risk Understanding Cause & Effect Designing & Analyzing Processes Group Creativity Selecting & Decision Making Five Ws Process Redesign Pull Process Mapping OEE
  3. 3. www.citoolkit.com Visual Management 3 A business management approach that communicates important information in a visual and real-time manner
  4. 4. www.citoolkit.com Visual Management 4 A system of labels, signs, markings, information displays, and visual guides instead of written instructions ///
  5. 5. www.citoolkit.com Visual Management 5 Lean organizations rely heavily on visual management to detect abnormalities, reinforce standards, and ensure stability and safety are maintained in the workplace A Lean leader should ensure that these visuals are useful and are being used constantly
  6. 6. www.citoolkit.com Visual Management 6 A good illustration of visual management are road signs, traffic lights and lane markers on the road The messages they convey are so clear that when you see a traffic light for example, you know exactly what you should be doing
  7. 7. www.citoolkit.com Visual Management 7 Research shows that people tend to learn and process information more visually Our brains simply respond better and faster to colors, shapes, patterns, graphics and pictures
  8. 8. www.citoolkit.com Visual Management 8 Just as road signs are easier to understand than written signs, workplace visuals are easier to understand than written instructions Therefore, effective workplace visuals can have a positive impact on safety, productivity, quality, and on-time delivery
  9. 9. www.citoolkit.com Visual Management 9 The aim is to enable anyone working in the workplace to be able to assess the current situation at a glance This should bring the workplace to the point where all problems, abnormalities and waste to be immediately recognized
  10. 10. www.citoolkit.com Visual Management 10 When problems and deviations are visible and apparent to all, immediate corrective action can be taken This will increase the efficiency and effectiveness of the processes
  11. 11. www.citoolkit.com Visual Management 11 Workplace visuals can also play an important role in job training by eliminating the need for constant supervision Employees would need less supervision because they understand the standards, see the results, and know exactly what to do
  12. 12. www.citoolkit.com Visual Management 12 Employees need visuals that show what is expected from them and to keep them informed about production status and customer needs
  13. 13. www.citoolkit.com Visual Management 13 Visual management can also be used to share goals and ideas, indicate safety risks, promote safe behavior at work, and to report team and Kaizen progress
  14. 14. www.citoolkit.com Visual Management 14 Eliminates confusion and creates stability to the environment, equipment and work performed Increases the awareness of error conditions and waste Replaces difficult to understand paperwork BENEFITS Improves compliance to health, safety and environmental regulatory requirements Improves employees’ involvement and morale Reduces the opportunity for miscommunication Reinforces continuous improvement Eliminates the need for time consuming meetings Improves the communication and handover between different shifts 01 02 03 04 05 06 07 08 09
  15. 15. www.citoolkit.com Visual Management 15 Serves as the key sustaining force for many lean techniques 5S Standard work Pull production Total productive maintenance (TPM) Visual Management Quick changeover
  16. 16. www.citoolkit.com Visual Management 16 Especially important during the early phase of Lean implementation
  17. 17. www.citoolkit.com Visual Management 17 Types of Visual Controls STATUS Visuals to display the status of processes, projects, production, productivity and performance INSTRUCTION Visuals to communicate SOPs, work-related information, and workplace organization and maintenance activities INFORMATION Visuals to show identity, directions, strategy, customer expectations and compliance requirements Visual management includes a wide range of visual controls that help making all workplace elements and processes more visually apparent
  18. 18. www.citoolkit.com Visual Management 18 Types of Visual Controls – Useful Questions STATUS What is the status now? What is happening against what should be happening? Is there any waste in the process? Are there any problems or issues? INSTRUCTION What should I do? When should I do it? How to do it correctly? How to do it safely? How to organize this area? How to store this item? When shall I reorder? INFORMATION Where am I now? Where am I going to? Who works here? What is this machine? What are customers & regulatory needs? Is the area, behavior, or condition safe?
  19. 19. www.citoolkit.com Visual Management 19 Many techniques and principles rely on visual management INSTRUCTION Work-related instructions 5S TPM Standard work INFORMATION Safety Visuals Signage Marking Posters & banners STATUS Performance metrics Kaizen progress Ideas & projects Andon lights Benchmark & best practices
  20. 20. www.citoolkit.com Visual Management 20 Safety visuals are important to keep the facility safe and environmentally friendly Play an important role in reducing injuries, incidents, near-misses and occupational diseases by reducing unsafe behaviors and conditions Safety Visuals
  21. 21. www.citoolkit.com Visual Management 21 Think of the manual of an airplane . . . Safety Visuals
  22. 22. www.citoolkit.com Visual Management 22 Safety signs and markings often use bright coloring to attract attention Danger ! Warning ! Caution ! Notice Safety Visuals
  23. 23. www.citoolkit.com Visual Management 23 Safety signage, hazard warnings and safety instructions should be provided at the point of need Safety Visuals
  24. 24. www.citoolkit.com Visual Management 24 It’s important to properly identify the locations of fire protection equipment, safety showers, eye wash stations, personal protective equipment, and first aid stations Safety Visuals And to identify when and where to use personal protective equipment
  25. 25. www.citoolkit.com Visual Management 25 All disconnect switches for every electrically powered equipment should be clearly marked Safety Visuals
  26. 26. www.citoolkit.com Visual Management 26 Wayfinding and directional signage help people find the way around They direct people from point to point and confirm the progress along a route Signage
  27. 27. www.citoolkit.com Visual Management 27 Warning signs such as do not enter and no-smoking signs Signage
  28. 28. www.citoolkit.com Visual Management 28 Proper marking of the different elements in the workplace is important to avoid mistakes and increase efficiency and safety Marking Marking of machines, equipment & production lines Marking floors and aisles Marking of pipelines and valves Marking of materials and finished goods Marking of offices, rooms, work cells and storage areas Marking of emergency lanes and exit routes
  29. 29. www.citoolkit.com Visual Management 29 Marking of machines, equipment and production lines by coloring and labeling each Marking
  30. 30. www.citoolkit.com Visual Management 30 Marking of offices, rooms, work cells and storage areas Marking
  31. 31. www.citoolkit.com Visual Management 31 Floor marking is used to improve the layout of the workplace and mark critical safety and security areas Marking
  32. 32. www.citoolkit.com Visual Management 32 Marking Aisle ways and traffic lanes Material or product held for inspection Scrap, rework, and red tag areas Raw materials Finished goods Work in progress Physical and health risk areas Areas to be kept clear for operational reasons Areas to be kept clear for safety reasons Floor Color Coding Standards These colors are widely accepted and comply with international standards
  33. 33. www.citoolkit.com Visual Management 33 Pipe marking communicates all the necessary information about the pipelines in the workplace Arrows are used to indicate the flow direction while colors often indicate the nature of the content Marking You may also post the labels on the pipelines
  34. 34. www.citoolkit.com Visual Management 34 Pipeline Color Coding Standards Toxic and corrosive fluids e.g., hydrofluoric acid Fire quenching water or other fluids used in the fire fighting system Water e.g., cooling and boiling water Flammable liquids and gases e.g., hydrogen Combustible fluids e.g., acetic acid Air e.g., compressed air Marking These colors are widely accepted and comply with international standards
  35. 35. www.citoolkit.com Visual Management 35 Using of posters and banners can reinforce business goals and values and promotes awareness of safety and wellbeing among employees Posters & Banners TIM WOODS
  36. 36. www.citoolkit.com Visual Management 36 It is recommended to post visual work-related instructions and trouble logs at every machine Work- related
  37. 37. www.citoolkit.com Visual Management 37 A strong visual management system seeks to promote consistency and create process stability Standard work visuals help minimize production errors & ensure activities are always performed by all in the most efficient and effective way Standard work
  38. 38. www.citoolkit.com Visual Management 38 These visuals includes procedures, work instructions, check sheets, checklists, flowcharts, schedules, photos and one- point-lessons Standard work
  39. 39. www.citoolkit.com Visual Management 39 Process specifications and standard operating procedures need to be posted at each machine or workstation Standard work
  40. 40. www.citoolkit.com Visual Management 40 Visual controls are often used in conjunction with color standards to enhance clarity and workplace communication 17 18 19 20 7 8 13 14 5 6 11 12 9 10 15 16 1 2 3 4 Zero lost cases 1-2 lost cases More than 2 lost cases Example - A map for the areas which have the most safety incidents that resulted in lost time Standard work
  41. 41. www.citoolkit.com Visual Management 41 The best visuals are those that include photos and drawings, and those that are placed at the point of need Good Can Pin Hole Body Dent Neck Scratch Visuals of good and bad parts are used to improve defect detection Standard work
  42. 42. www.citoolkit.com Visual Management 42 The 5S methodology involves many visual management practices that can help creating a more organized workplace 5S
  43. 43. www.citoolkit.com Visual Management 43 The second step of the 5S methodology ‘set-in-order’ promotes the use of colors and labels to clearly mark storage locations Scrap 1 Scrap 2 Scrap 3 REJECT PARETO STACK 5S also promotes the use of many inventory management techniques to define inventory levels and reorder triggers 5S
  44. 44. www.citoolkit.com Visual Management 44 The min-max system is one of the simplest visual methods to control inventory mainly for low-volume items It suggests setting upper and lower inventory limits for each item Max. Min. Reorder point MIN-MAX SYSTEM PART A PART B 5S An order should be placed when the minimum level is reached
  45. 45. www.citoolkit.com Visual Management 45 In the two-bin system, the items are stored at two different bins The first is intended for supplying the current demand and the second for supplying the demand during the replenishment period TWO-BIN SYSTEM 5S
  46. 46. www.citoolkit.com Visual Management 46 Post photos about how an area should be organized to remind people of the standard 5S
  47. 47. www.citoolkit.com Visual Management 47 TPM visuals can be effective in identifying and preventing abnormalities from turning into failures If something is not normal, we want to make that as apparent as possible TPM
  48. 48. www.citoolkit.com Visual Management 48 Marking gauges, oil levels and lube points are examples of visual controls that enable employees to easily detect abnormalities and out-of-specification conditions TPM
  49. 49. www.citoolkit.com Visual Management 49 Color coding can be applied to gauges and other measuring devises to visually monitor whether process parameters remain within acceptable or safe ranges BEFORE AFTER TPM
  50. 50. www.citoolkit.com Visual Management 50 Colored sleeves can be used to identify all the tools within a particular kit, team or area TEAM 1 TEAM 2 This will help reducing the time spent looking for lost tools TPM
  51. 51. www.citoolkit.com Visual Management 51 Transparent machine guards and covers will enable to see the running process of the machine, and as a result, the machine will be stopped less frequently TPM
  52. 52. www.citoolkit.com Visual Management 52 An area information board is used to post visual information regarding the status of an operation for a specific area Area Boards Laminated A4 size sheets Whiteboard Area information board
  53. 53. www.citoolkit.com Visual Management 53 It is useful to communicate status updates to ensure all employees are on the same page Area Boards It is not a kind of wallpaper but a real team collaboration tool, and should be part of the daily management process
  54. 54. www.citoolkit.com Visual Management 54 Daily meetings can be conducted in front of the board to discuss the previous day’s issues and plan for the work ahead Area Boards
  55. 55. www.citoolkit.com Visual Management 55 Reviewing the board regularly is very important for the meetings to be productive Data should be collected on a daily basis to update the board Area Boards
  56. 56. www.citoolkit.com Visual Management 56 LIVE Information on boards should be fresh and up-to-date including schedules and customer requirements Area Boards A good visual board is an ALIVE board!
  57. 57. www.citoolkit.com Visual Management 57 These stand-up meetings can also be useful to facilitate handovers in multi-shift operations SHIFT-A SHIFT-B SHIFT-C Area Boards
  58. 58. www.citoolkit.com Visual Management 58 All aspects of an operation can be discussed during the meetings Safety Quality Cost Production & Productivity Teamwork Customer CI Projects Innovation Area Boards
  59. 59. www.citoolkit.com Visual Management 59 What to post . . . Quality Area Boards News, notifications, announcements, policy changes, events, accomplishments, records, ideas, best practices, etc. What else?
  60. 60. www.citoolkit.com Visual Management 60 Remember that status visuals are used to display the status of projects, processes, production, productivity & performance Area Boards STATUS Performance metrics Andon lights Benchmark & best practices Kaizen progress Ideas & projects PERFORMANCE PRODUCTION PROJECTS PERFORMANCE PROJECTS
  61. 61. www.citoolkit.com Visual Management 61 Area information boards can be used to display . . . Benchmark information Kaizen progress Best practices Operational records The status of improvement projects Other teamwork activities Area Boards
  62. 62. www.citoolkit.com Visual Management 62 A workplace without a display of performance metrics is like a car without a speedometer You may know where you are going but you have no idea when you will reach your destination Metrics
  63. 63. www.citoolkit.com Visual Management 63 Performance metrics should be displayed in a visually appealing way to allow people to get insight into how the operation is performing Metrics
  64. 64. www.citoolkit.com Visual Management 64 BENEFITS of Visual Performance Boards Metrics Creates a sense of purpose and drives motivation Serves as a communication tool for others outside of the team Directs the team discussions around priority areas Presents the performance of a team, department, process & business
  65. 65. www.citoolkit.com Visual Management 65 Customized performance charts allow to compare actual performance against target Metrics This can be shown on daily, weekly, monthly or quarterly basis
  66. 66. www.citoolkit.com Visual Management 66 Monthly performance charts that show averages across time make it hard to understand and analyze the problems, and therefore, hard to improve Metrics CUSTOMER COMPLAINTS COST OF QUALITY
  67. 67. www.citoolkit.com Visual Management 67 Performance information should be meaningful, easy to understand, free of technical terms, accurate & up-to-date Metrics Everyone must be able to understand the message
  68. 68. www.citoolkit.com Visual Management 68 Real-time visual dashboards are used to improve production control They make it easy to identify error conditions and allow to quickly respond to issues that would influence productivity Metrics
  69. 69. www.citoolkit.com Visual Management 69 Production Summary Boards are used to monitor the output of an operation and see if it meets customer demand They may also display other information such as efficiency, Takt time, etc. Metrics
  70. 70. www.citoolkit.com Visual Management 70 Production summary boards should be visible in the workplace, and everyone should be able to see where production stands This allows production and maintenance teams to quickly resolve process issues that may occur during production Metrics
  71. 71. www.citoolkit.com Visual Management 71 Process-related metrics need to be displayed near the machine or work cell While general plant metrics need to be posted in a central location where everyone can see it easily Metrics
  72. 72. www.citoolkit.com Visual Management 72 Andon lights are powerful visual tools which are installed on production machines to indicate their current status Since they are visible from a distance, they are very useful in bringing immediate attention to problems as soon as they arise Andon
  73. 73. www.citoolkit.com Visual Management 73 For example, a light may turn on to indicate a shortage of raw materials, awaiting parts, or the need for maintenance The system can include means to stop the process, so the issue get resolved Andon
  74. 74. www.citoolkit.com Visual Management 74 Each color represents a particular state of the machine or production line Operation is normal Operation is down (no order, maintenance, cleaning, quality checks, etc.) Operation is down for unknown reasons and needs further investigation Andon
  75. 75. www.citoolkit.com Visual Management 75 Remember that your goal is to make the area more informative Decide who are your target audience Let the teams help creating the visual controls and boards Include reviewing the visual controls in your Gemba walks Design and use a checklist to evaluate your visual controls Create a guide that describes the key elements associated with the visual management system Decide where you need to implement visual management TIPS to create an effective visual management system Mark floors, add signs, label storage areas, post standard work, create visual boards, etc. Determine the type of information that needs to be conveyed Use the colors and standards that are being used consistently Decide who are going to be involved in the implementation effort
  76. 76. www.citoolkit.com Visual Management 76 An effective visual management system . . . Displays customer needs & expectations Shows identity and directions Easy to use and understand Displays performance targets and results Relates to the strategy of the company Communicates standards and instructions Makes abnormalities apparent Links to action
  77. 77. www.citoolkit.com Visual Management 77 Visual management is not just making charts and metrics visible on a wall! It is a real-time system of marking and visuals that allows teams to respond promptly to signals to solve issues and support the production process. Summary
  78. 78. www.citoolkit.com Visual Management 78 Further Information It is very common to conduct Kaizen events where the focus is to enhance the visuality of a specific process or work area
  79. 79. www.citoolkit.com Visual Management 79 Further Information Visual management is a collaborative process, and people engagement is key to the contribution they will provide later Listen to them, involve them, and let them own the visuals See, know, and act collaboratively
  80. 80. www.citoolkit.com Visual Management 80 Further Information If people from outside the area are updating the boards, then it will be seen that management are owning them In this case, don’t expect anyone to read the boards or even care what’s in them
  81. 81. www.citoolkit.com Visual Management 81 Further Information Can also be useful for support functions in a production environment (such as accounting, sales, engineering and R&D) and in the service sector
  82. 82. www.citoolkit.com Visual Management 82 Further Information - Examples in the Service Sector The queue counter display in a bank. A sign indicating cleaning in progress or wet floor in a washroom in a shopping mall. A sign indicating the different types of waste disposal bins in a hotel lobby. The signs in an airport that direct passengers to the luggage claim area.
  83. 83. www.citoolkit.com Visual Management 83 Further Information A Kanban provides a visual method of inventory control and uses color coded cards to supports a pull system DOING TO DO DONE PROGRESS TRACKING BOARD
  84. 84. www.citoolkit.com Visual Management 84 Examples of how to eliminate waste using VM Reduce waiting by visually defining work sequence. Reduce defects by quickly responding to Andon signals. Prevent overproduction by visually displaying production actuals and targets. Reduce motion by ensuring all parts and tools are accessible and recognizable. Further Information Prevent excess transportation by labeling and marking locations and paths. Minimize the non-use of skills by visually sharing problems and working together to solve them. Eliminate excess inventory by improving visibility of storage. Eliminate excess inventory by improving visibility of storage.

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