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CITOOLKIT
Visual Management
The Main Components of an Effective Visual Management System
citoolkit.com
Definition
A business management approach that communicates important
information in a visual and real-time manner .
Visual Management 2
citoolkit.com
Definition
It is a system of labels, signs, markings, information displays, and visual
guides instead of written instructions.
Visual Management 3
///
Consists of simple visual techniques that are placed at the Gemba.
citoolkit.com
Definition
Lean organizations rely heavily on visual management to detect
abnormalities, reinforce standards, and ensure stability and safety are
maintained in the workplace.
Visual Management 4
A Lean leader should ensure that
these visuals are useful and are
being used constantly.
citoolkit.com
Definition
A good illustration of visual management are road signs, traffic lights and
lane markers on the road.
Visual Management 5
The messages they convey are so clear that when you see a traffic light for example,
you know exactly what you should be doing.
citoolkit.com
Definition
Research shows that people tend to learn and process information more
visually.
Visual Management 6
Our brains simply respond better and
faster to colors, shapes, patterns,
graphics and pictures.
citoolkit.com
Uses
Just as road signs are easier to understand than written signs, workplace
visuals are easier to understand than written instructions.
Visual Management 7
Therefore, effective workplace visuals can have a positive impact on safety, productivity,
quality, and on-time delivery.
citoolkit.com
Uses
The aim is to enable anyone working in the workplace to be able to assess
the current situation at a glance.
Visual Management 8
This should bring the workplace to the point where all problems, abnormalities and
waste to be immediately recognized.
citoolkit.com
Uses
Workplace visuals can play an important role in job training by eliminating
the need for constant supervision.
Visual Management 9
Employees would need less
supervision because they understand
the standards, see the results, and
know exactly what to do
Employees need visuals that show what is expected from them and to keep them
informed about production status and customer needs.
citoolkit.com
Uses
Visual management can also be used to . . .
Visual Management 10
Share goals and
ideas
Promote safe
behavior at work
Indicate safety
risks
Report team and
Kaizen progress
citoolkit.com
Benefits
When problems and deviations are visible and apparent to all, immediate
corrective action can be taken.
Visual Management 11
This will increase the efficiency
and effectiveness of the
processes.
citoolkit.com
Benefits
Visual Management 12
Increases the awareness of error
conditions and waste
02
Replaces difficult to understand
paperwork
03
Improves compliance to health,
safety and environmental regulatory
requirements
05
Reduces the opportunity for
miscommunication
06
Improves the communication and
handover between different shifts
07
Eliminates the need for time
consuming meetings
08
Reinforces continuous
improvement
09
Eliminates confusion and creates
stability to the environment,
equipment and work performed
01
Improves employees’
involvement and morale
04
citoolkit.com
Benefits
Serves as the key sustaining force for many lean techniques.
Visual Management 13
5S
Standard work
Pull
production
Total
productive
maintenance
(TPM)
Visual
Management
Quick
changeover
citoolkit.com
Benefits
Especially important during the early phase of Lean implementation.
Visual Management 14
Many organizations start their
Lean journey with visual
management to help uncover
hidden waste and
abnormalities.
citoolkit.com
Types of Visual Controls
Visual management includes a wide range of visual controls that help
making all workplace elements and processes more visually apparent.
Visual Management 15
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
citoolkit.com
Types of Visual Controls
Visual Management 16
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 issues or
problems?
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?
citoolkit.com
Types of Visual Controls
Many techniques and principles rely on visual management.
Visual Management 17
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
citoolkit.com
Safety Visuals
Safety visuals are important to keep the facility safe and environmentally
friendly.
Visual Management 18
They play an important role in
reducing injuries, incidents, near-
misses and occupational diseases by
reducing unsafe behaviors and
conditions
They alert employees and visitors to potentially hazardous locations and situations.
Safety
Visuals
citoolkit.com
Safety Visuals
Think of the manual of an airplane . . .
Visual Management 19
Safety
Visuals
citoolkit.com
Safety Visuals
Safety signs and markings often use bright coloring to attract attention.
Visual Management 20
Danger
!
Warning
!
Caution
!
Notice
Using bright colors such as red, yellow,
orange, and fluorescent shades ensures
that signs and markings can be easily
spotted even from a distance, in low-
light conditions, and at night
Safety
Visuals
citoolkit.com
Safety Visuals
Safety signage, hazard warnings and safety instructions should be provided
at the point of need.
Visual Management 21
Providing safety information directly where it is needed helps to minimize confusion,
potential errors, and can effectively prevent accidents or injuries.
Safety
Visuals
citoolkit.com
Safety Visuals
It’s important to properly identify the locations of fire protection equipment,
safety showers, eye wash stations, personal protective equipment, and first
aid stations.
Visual Management 22
Identify when and where to use
personal protective equipment
Safety
Visuals
citoolkit.com
Safety Visuals
All disconnect switches for every electrically powered equipment should be
clearly marked.
Visual Management 23
Clear markings prevent accidental operation, allowing for rapid identification
during emergencies and ensuring that power can be shut off promptly to prevent
further damage or risks
Safety
Visuals
citoolkit.com
Signage
Wayfinding and directional signage help people find the way around.
They direct people from point to point and confirm the progress along a
route.
Visual Management 24
Signage
citoolkit.com
Signage
Warning signs alert about certain activities such as do not enter and no-
smoking signs.
Visual Management 25
Signage
citoolkit.com
Marking
Proper marking of the different elements in the workplace is important to
avoid mistakes and increase efficiency and safety.
Visual Management 26
Marking of materials and finished goods
Marking of emergency lanes and exit routes
Marking floors and aisles
Marking of machines, equipment & production lines
Marking of offices, rooms, work cells and storage areas
Marking of pipelines and valves
Marking
citoolkit.com
Marking
Marking of machines, equipment and production lines by coloring and
labeling each.
Visual Management 27
When machines and equipment are clearly identified, it becomes easier for employees
and trainees to associate each with its specific purpose or function.
Marking
citoolkit.com
Marking
Marking of offices, rooms, work cells and storage areas.
Visual Management 28
This enhances workplace efficiency and facilitates easy navigation for employees.
Marking
citoolkit.com
Marking
Floor marking is used to improve the layout of the workplace and mark
critical safety and security areas.
Visual Management 29
Marking
citoolkit.com
Floor Color Coding Standards
Visual Management 30
These colors are widely accepted and comply with international standards.
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
Marking
citoolkit.com
Marking
Pipe marking communicates all the necessary information about the
pipelines in the workplace.
Visual Management 31
Labels can also be posted on the pipelines
Marking
Arrows are used to indicate
the flow direction while colors
often indicate the nature of
the content.
citoolkit.com
Pipeline Color Coding Standards
These colors are widely accepted and comply with international standards.
Visual Management 32
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
citoolkit.com
Posters and Banners
Using of posters and banners can reinforce business goals and values and
promotes awareness of safety and wellbeing among employees.
Visual Management 33
TIM
WOODS
Posters &
Banners
citoolkit.com
Work Related Instructions
It is recommended to post visual work-related instructions and trouble logs
at every machine.
Visual Management 34
Work-
related
Reduces the need for verbal or written instructions
Provides immediate guidance to operators
Accessible to workers who may have language barriers
Promotes a culture of transparency and accountability
citoolkit.com
Standard Work
A strong visual management system seeks to promote consistency and
create process stability.
Visual Management 35
Standard
Work
Standard work visuals help
minimize production errors and
ensure activities are always
performed by all in the most
efficient and effective way.
Visual management should be built on standardized work
citoolkit.com
Standard Work
Standard work visuals includes procedures, work instructions, check sheets,
checklists, flowcharts, schedules, photos and one-point-lessons.
Visual Management 36
Standard
Work
citoolkit.com
Standard Work
A good practice is to post process specifications and standard operating
procedures at each machine or workstation.
Visual Management 37
Standard
Work
citoolkit.com
Standard Work
Visual controls are often used in conjunction with color standards to
enhance clarity and workplace communication.
Visual Management 38
Standard
Work
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
citoolkit.com
Standard Work
The best visuals are those that include photos and drawings, and those
that are placed at the point of need.
Visual Management 39
Standard
Work
Good Can Pin Hole Body Dent Neck Scratch
Visuals of good and
bad parts are used to
improve defect
detection
citoolkit.com
5S
The 5S methodology involves many visual management practices that can
help creating a more organized workplace.
Visual Management 40
5S
The 2nd 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.
citoolkit.com
5S
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.
Visual Management 41
5S
Max.
Min.
Reorder
point
MIN-MAX SYSTEM
PART A PART B
An order should
be placed when
the minimum
level is reached
citoolkit.com
5S
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.
Visual Management 42
5S
TWO-BIN SYSTEM
citoolkit.com
5S
Another example of using visual management to improve workplace
organization is posting photos about how an area should be organized to
remind people of the standard.
Visual Management 43
5S
citoolkit.com
Total Productive Maintenance (TPM)
TPM visuals can be effective in identifying and preventing abnormalities
from turning into failures.
Visual Management 44
TPM
If something is not normal, we
want to make that as apparent as
possible!
citoolkit.com
Total Productive Maintenance (TPM)
Marking gauges, oil levels and lube points are examples of visual controls
that enable employees to easily detect abnormalities and out-of-
specification conditions.
Visual Management 45
TPM
citoolkit.com
Total Productive Maintenance (TPM)
Color coding can be applied to gauges and other measuring devises to
visually monitor whether process parameters remain within acceptable or
safe ranges.
Visual Management 46
TPM
BEFORE AFTER
citoolkit.com
Total Productive Maintenance (TPM)
Colored sleeves can be used to identify all the tools within a particular kit,
team or area.
Visual Management 47
TPM
TEAM 1 TEAM 2
This will help reducing the time spent looking for lost tools, which will reduce repair
time and repair cost.
citoolkit.com
Total Productive Maintenance (TPM)
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.
Visual Management 48
TPM
citoolkit.com
Area Boards
An area information board is used to post visual information regarding the
status of an operation for a specific area.
Visual Management 49
Area
Boards
Laminated
A4 size sheets
Whiteboard
Area information
board
They should be placed at visible locations to promote team engagement.
citoolkit.com
Area Boards
It is useful to communicate status updates to ensure all employees are on
the same page.
Visual Management 50
Area
Boards
It is not just a kind of wallpaper but a real team collaboration tool, and should be part
of the daily management process.
citoolkit.com
Area Boards
Daily meetings can be conducted in front of the board to discuss the
previous day’s issues and plan for the work ahead.
Visual Management 51
Area
Boards
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.
citoolkit.com
Area Boards
Information on boards should be fresh and up-to-date including schedules
and customer requirements.
Visual Management 52
Area
Boards
LIVE
A good visual board is an ALIVE board!
citoolkit.com
Area Boards
These stand-up meetings can also be useful to facilitate handovers in multi-
shift operations.
Visual Management 53
Area
Boards
Plot the data of each shift independently
SHIFT-A SHIFT-B SHIFT-C
citoolkit.com
Area Boards
All aspects of an operation can be discussed during the meetings.
Visual Management 54
Area
Boards
Safety
Quality
Cost Production &
Productivity
Teamwork
Customer
CI Projects
Innovation
citoolkit.com
Area Boards
What to post?
Visual Management 55
Area
Boards
Quality
Consider also posting news, notifications, announcements, policy changes, events,
accomplishments, records, ideas, best practices, etc.
citoolkit.com
Area Boards
Remember that status visuals are used to display the status of projects,
processes, production, productivity and performance.
Visual Management 56
Area
Boards
STATUS
Performance metrics
Kaizen
progress
Ideas &
projects
Andon
lights
Benchmark &
best practices
PERFORMANCE
PRODUCTION
PROJECTS
PERFORMANCE
PROJECTS
citoolkit.com
Area Boards
Area information boards can be used to display . . .
Visual Management 57
Area
Boards
Benchmark
information
Kaizen
progress
Best practices
and lessons
learned
Operational
records
The status of
improvement
projects
Other
teamwork
activities
citoolkit.com
Performance Metrics
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.
Visual Management 58
Metrics
Performance metrics should be displayed in a visually appealing way to allow people to
get insight into how the operation is performing.
citoolkit.com
Performance Metrics
Benefits of Visual Performance Boards . . .
Visual Management 59
Metrics
Presents the
performance of a team,
department, process &
business
Directs the team
discussions around
priority areas
Creates a sense of
purpose and drives
motivation
Serves as a
communication tool for
others outside of the
team
citoolkit.com
Performance Metrics
Customized performance charts allow to compare actual performance
against target.
Visual Management 60
Metrics
This can be shown on daily, weekly, monthly or quarterly basis
citoolkit.com
Performance Metrics
Performance information should be meaningful, easy to understand, free
of technical terms, accurate and up-to-date.
Visual Management 61
Metrics
Everyone must be able to understand
the message.
Keep them as simple as possible.
citoolkit.com
Performance Metrics
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.
Visual Management 62
Metrics
citoolkit.com
Performance Metrics
Production Summary Boards are used to monitor the output of an
operation and see if it meets customer demand.
Visual Management 63
Metrics
They may also display other information such as efficiency, Takt time, etc.
citoolkit.com
Performance Metrics
Production summary boards should be visible in the workplace, and
everyone should be able to see where production stands.
Visual Management 64
Metrics
This allows production and
maintenance teams to quickly
resolve process issues that
may occur during production.
citoolkit.com
Performance Metrics
Process-related metrics need to be displayed near the machine or work
cell.
Visual Management 65
Metrics
While general plant metrics need
to be posted in a central location
where everyone can see it easily.
citoolkit.com
Andon Lights
Andon lights are powerful visual tools which are installed on production
machines to indicate their current status.
Visual Management 66
Andon
Since they are visible from a distance, they are very useful in bringing immediate
attention to problems as soon as they arise.
citoolkit.com
Andon Lights
For example, a light may turn on to indicate a shortage of raw materials,
awaiting parts, or the need for maintenance.
Visual Management 67
Andon
The system can include means to stop the process, so the issue get resolved.
citoolkit.com
Andon Lights
Each color represents a particular state of the machine or production line.
Visual Management 68
Andon
Operation is
normal
Operation is down
(no order,
maintenance,
cleaning, quality
checks, etc.)
Operation is down
for unknown
reasons and
needs further
investigation
citoolkit.com
Tips to Create an Effective Visual Management System
Visual Management 69
Use the colors and standards
that are being used
consistently
Let the teams help creating the
visual controls and boards
Decide where you need to
implement visual management
Determine the type of
information that needs to be
conveyed
Decide who are your target
audience
Create a guide that describes
the key elements associated
with the visual management
system
Remember that your goal is to
make the area more
informative
Decide who are going to be
involved in the implementation
effort
Mark floors, add signs, label
storage areas, post standard
work, create visual boards, etc.
Include reviewing the visual
controls in your Gemba walks
Design and use a checklist to
evaluate your visual controls
citoolkit.com
Tips to Create an Effective Visual Management System
An effective visual management system . . .
Visual Management 70
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
citoolkit.com
Summary
Visual management is not just making charts and metrics visible on a wall!
Visual Management 71
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
citoolkit.com
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.
Visual Management 72
For example, organizing the workplace using 5S, stabilizing how work is performed
using standard work, or stabilizing equipment performance and reliability using TPM.
citoolkit.com
Further Information
Visual management is a collaborative process, and people engagement is
key to the contribution they will provide later.
Visual Management 73
Listen to people, involve them, and let them own the visuals.
citoolkit.com
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.
Visual Management 74
citoolkit.com
Further Information
Visual management can also be useful for support functions in the
production environment (such as accounting, sales, engineering and R&D)
and in the service sector.
Visual Management 75
citoolkit.com
Further Information
Examples in the Service Sector . . .
Visual Management 76
The queue counter
display in a bank
A sign indicating the
different types of waste
disposal bins in a hotel
lobby
A sign indicating
cleaning in progress or
wet floor in a washroom
in a shopping mall
The signs in an airport
that direct passengers
to the luggage claim
area
citoolkit.com
Further Information
A Kanban provides a visual method of inventory control and uses color-
coded cards to support a pull system.
Visual Management 77
DOING
TO DO DONE
PROGRESS TRACKING BOARD
citoolkit.com
Examples of How to Eliminate Waste using Visual Management
Visual Management 78
Minimize the non-use of skills by
visually sharing problems and working
together to solve them.
Eliminate excess inventory by
improving visibility of storage.
Reduce motion by ensuring all parts
and tools are accessible and
recognizable.
Eliminate excess inventory by
improving visibility of storage.
Reduce defects by quickly responding to
Andon signals.
Prevent overproduction by visually
displaying production actuals and
targets.
Prevent excess transportation by
labeling and marking locations and
paths.
Reduce waiting by visually defining work
sequence.
citoolkit.com
Example from a Production Environment
Visual Management 79
2 Andon lights
1 Safety sign
4 Machine identity
3 Floor marking
5 Visual instructions
6 Gauge marking
citoolkit.com
Kamishibai Board
A Kamishibai board is a visual management method that is used to manage
routine activities in a workplace.
It can be used to audit safety and security measures as well as to confirm
that standard work is being undertaken by all employees.
Visual Management 80
In its simplest form, it consists of a board
and multiple cards that displays selected
activities to be performed.
citoolkit.com
Kamishibai Board
Typically, each card is red on one side and green on the other to indicate
whether the activity has been completed or not.
Visual Management 81
WEEKLY
DAILY
© Copyright Citoolkit.com. All Rights Reserved.
CITOOLKIT
Made with by
The Continuous Improvement Toolkit
www.citoolkit.com

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The Main Components of an Effective Visual Management System

  • 1. CITOOLKIT Visual Management The Main Components of an Effective Visual Management System
  • 2. citoolkit.com Definition A business management approach that communicates important information in a visual and real-time manner . Visual Management 2
  • 3. citoolkit.com Definition It is a system of labels, signs, markings, information displays, and visual guides instead of written instructions. Visual Management 3 /// Consists of simple visual techniques that are placed at the Gemba.
  • 4. citoolkit.com Definition Lean organizations rely heavily on visual management to detect abnormalities, reinforce standards, and ensure stability and safety are maintained in the workplace. Visual Management 4 A Lean leader should ensure that these visuals are useful and are being used constantly.
  • 5. citoolkit.com Definition A good illustration of visual management are road signs, traffic lights and lane markers on the road. Visual Management 5 The messages they convey are so clear that when you see a traffic light for example, you know exactly what you should be doing.
  • 6. citoolkit.com Definition Research shows that people tend to learn and process information more visually. Visual Management 6 Our brains simply respond better and faster to colors, shapes, patterns, graphics and pictures.
  • 7. citoolkit.com Uses Just as road signs are easier to understand than written signs, workplace visuals are easier to understand than written instructions. Visual Management 7 Therefore, effective workplace visuals can have a positive impact on safety, productivity, quality, and on-time delivery.
  • 8. citoolkit.com Uses The aim is to enable anyone working in the workplace to be able to assess the current situation at a glance. Visual Management 8 This should bring the workplace to the point where all problems, abnormalities and waste to be immediately recognized.
  • 9. citoolkit.com Uses Workplace visuals can play an important role in job training by eliminating the need for constant supervision. Visual Management 9 Employees would need less supervision because they understand the standards, see the results, and know exactly what to do Employees need visuals that show what is expected from them and to keep them informed about production status and customer needs.
  • 10. citoolkit.com Uses Visual management can also be used to . . . Visual Management 10 Share goals and ideas Promote safe behavior at work Indicate safety risks Report team and Kaizen progress
  • 11. citoolkit.com Benefits When problems and deviations are visible and apparent to all, immediate corrective action can be taken. Visual Management 11 This will increase the efficiency and effectiveness of the processes.
  • 12. citoolkit.com Benefits Visual Management 12 Increases the awareness of error conditions and waste 02 Replaces difficult to understand paperwork 03 Improves compliance to health, safety and environmental regulatory requirements 05 Reduces the opportunity for miscommunication 06 Improves the communication and handover between different shifts 07 Eliminates the need for time consuming meetings 08 Reinforces continuous improvement 09 Eliminates confusion and creates stability to the environment, equipment and work performed 01 Improves employees’ involvement and morale 04
  • 13. citoolkit.com Benefits Serves as the key sustaining force for many lean techniques. Visual Management 13 5S Standard work Pull production Total productive maintenance (TPM) Visual Management Quick changeover
  • 14. citoolkit.com Benefits Especially important during the early phase of Lean implementation. Visual Management 14 Many organizations start their Lean journey with visual management to help uncover hidden waste and abnormalities.
  • 15. citoolkit.com Types of Visual Controls Visual management includes a wide range of visual controls that help making all workplace elements and processes more visually apparent. Visual Management 15 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
  • 16. citoolkit.com Types of Visual Controls Visual Management 16 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 issues or problems? 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?
  • 17. citoolkit.com Types of Visual Controls Many techniques and principles rely on visual management. Visual Management 17 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
  • 18. citoolkit.com Safety Visuals Safety visuals are important to keep the facility safe and environmentally friendly. Visual Management 18 They play an important role in reducing injuries, incidents, near- misses and occupational diseases by reducing unsafe behaviors and conditions They alert employees and visitors to potentially hazardous locations and situations. Safety Visuals
  • 19. citoolkit.com Safety Visuals Think of the manual of an airplane . . . Visual Management 19 Safety Visuals
  • 20. citoolkit.com Safety Visuals Safety signs and markings often use bright coloring to attract attention. Visual Management 20 Danger ! Warning ! Caution ! Notice Using bright colors such as red, yellow, orange, and fluorescent shades ensures that signs and markings can be easily spotted even from a distance, in low- light conditions, and at night Safety Visuals
  • 21. citoolkit.com Safety Visuals Safety signage, hazard warnings and safety instructions should be provided at the point of need. Visual Management 21 Providing safety information directly where it is needed helps to minimize confusion, potential errors, and can effectively prevent accidents or injuries. Safety Visuals
  • 22. citoolkit.com Safety Visuals It’s important to properly identify the locations of fire protection equipment, safety showers, eye wash stations, personal protective equipment, and first aid stations. Visual Management 22 Identify when and where to use personal protective equipment Safety Visuals
  • 23. citoolkit.com Safety Visuals All disconnect switches for every electrically powered equipment should be clearly marked. Visual Management 23 Clear markings prevent accidental operation, allowing for rapid identification during emergencies and ensuring that power can be shut off promptly to prevent further damage or risks Safety Visuals
  • 24. citoolkit.com Signage Wayfinding and directional signage help people find the way around. They direct people from point to point and confirm the progress along a route. Visual Management 24 Signage
  • 25. citoolkit.com Signage Warning signs alert about certain activities such as do not enter and no- smoking signs. Visual Management 25 Signage
  • 26. citoolkit.com Marking Proper marking of the different elements in the workplace is important to avoid mistakes and increase efficiency and safety. Visual Management 26 Marking of materials and finished goods Marking of emergency lanes and exit routes Marking floors and aisles Marking of machines, equipment & production lines Marking of offices, rooms, work cells and storage areas Marking of pipelines and valves Marking
  • 27. citoolkit.com Marking Marking of machines, equipment and production lines by coloring and labeling each. Visual Management 27 When machines and equipment are clearly identified, it becomes easier for employees and trainees to associate each with its specific purpose or function. Marking
  • 28. citoolkit.com Marking Marking of offices, rooms, work cells and storage areas. Visual Management 28 This enhances workplace efficiency and facilitates easy navigation for employees. Marking
  • 29. citoolkit.com Marking Floor marking is used to improve the layout of the workplace and mark critical safety and security areas. Visual Management 29 Marking
  • 30. citoolkit.com Floor Color Coding Standards Visual Management 30 These colors are widely accepted and comply with international standards. 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 Marking
  • 31. citoolkit.com Marking Pipe marking communicates all the necessary information about the pipelines in the workplace. Visual Management 31 Labels can also be posted on the pipelines Marking Arrows are used to indicate the flow direction while colors often indicate the nature of the content.
  • 32. citoolkit.com Pipeline Color Coding Standards These colors are widely accepted and comply with international standards. Visual Management 32 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
  • 33. citoolkit.com Posters and Banners Using of posters and banners can reinforce business goals and values and promotes awareness of safety and wellbeing among employees. Visual Management 33 TIM WOODS Posters & Banners
  • 34. citoolkit.com Work Related Instructions It is recommended to post visual work-related instructions and trouble logs at every machine. Visual Management 34 Work- related Reduces the need for verbal or written instructions Provides immediate guidance to operators Accessible to workers who may have language barriers Promotes a culture of transparency and accountability
  • 35. citoolkit.com Standard Work A strong visual management system seeks to promote consistency and create process stability. Visual Management 35 Standard Work Standard work visuals help minimize production errors and ensure activities are always performed by all in the most efficient and effective way. Visual management should be built on standardized work
  • 36. citoolkit.com Standard Work Standard work visuals includes procedures, work instructions, check sheets, checklists, flowcharts, schedules, photos and one-point-lessons. Visual Management 36 Standard Work
  • 37. citoolkit.com Standard Work A good practice is to post process specifications and standard operating procedures at each machine or workstation. Visual Management 37 Standard Work
  • 38. citoolkit.com Standard Work Visual controls are often used in conjunction with color standards to enhance clarity and workplace communication. Visual Management 38 Standard Work 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
  • 39. citoolkit.com Standard Work The best visuals are those that include photos and drawings, and those that are placed at the point of need. Visual Management 39 Standard Work Good Can Pin Hole Body Dent Neck Scratch Visuals of good and bad parts are used to improve defect detection
  • 40. citoolkit.com 5S The 5S methodology involves many visual management practices that can help creating a more organized workplace. Visual Management 40 5S The 2nd 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.
  • 41. citoolkit.com 5S 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. Visual Management 41 5S Max. Min. Reorder point MIN-MAX SYSTEM PART A PART B An order should be placed when the minimum level is reached
  • 42. citoolkit.com 5S 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. Visual Management 42 5S TWO-BIN SYSTEM
  • 43. citoolkit.com 5S Another example of using visual management to improve workplace organization is posting photos about how an area should be organized to remind people of the standard. Visual Management 43 5S
  • 44. citoolkit.com Total Productive Maintenance (TPM) TPM visuals can be effective in identifying and preventing abnormalities from turning into failures. Visual Management 44 TPM If something is not normal, we want to make that as apparent as possible!
  • 45. citoolkit.com Total Productive Maintenance (TPM) Marking gauges, oil levels and lube points are examples of visual controls that enable employees to easily detect abnormalities and out-of- specification conditions. Visual Management 45 TPM
  • 46. citoolkit.com Total Productive Maintenance (TPM) Color coding can be applied to gauges and other measuring devises to visually monitor whether process parameters remain within acceptable or safe ranges. Visual Management 46 TPM BEFORE AFTER
  • 47. citoolkit.com Total Productive Maintenance (TPM) Colored sleeves can be used to identify all the tools within a particular kit, team or area. Visual Management 47 TPM TEAM 1 TEAM 2 This will help reducing the time spent looking for lost tools, which will reduce repair time and repair cost.
  • 48. citoolkit.com Total Productive Maintenance (TPM) 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. Visual Management 48 TPM
  • 49. citoolkit.com Area Boards An area information board is used to post visual information regarding the status of an operation for a specific area. Visual Management 49 Area Boards Laminated A4 size sheets Whiteboard Area information board They should be placed at visible locations to promote team engagement.
  • 50. citoolkit.com Area Boards It is useful to communicate status updates to ensure all employees are on the same page. Visual Management 50 Area Boards It is not just a kind of wallpaper but a real team collaboration tool, and should be part of the daily management process.
  • 51. citoolkit.com Area Boards Daily meetings can be conducted in front of the board to discuss the previous day’s issues and plan for the work ahead. Visual Management 51 Area Boards 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.
  • 52. citoolkit.com Area Boards Information on boards should be fresh and up-to-date including schedules and customer requirements. Visual Management 52 Area Boards LIVE A good visual board is an ALIVE board!
  • 53. citoolkit.com Area Boards These stand-up meetings can also be useful to facilitate handovers in multi- shift operations. Visual Management 53 Area Boards Plot the data of each shift independently SHIFT-A SHIFT-B SHIFT-C
  • 54. citoolkit.com Area Boards All aspects of an operation can be discussed during the meetings. Visual Management 54 Area Boards Safety Quality Cost Production & Productivity Teamwork Customer CI Projects Innovation
  • 55. citoolkit.com Area Boards What to post? Visual Management 55 Area Boards Quality Consider also posting news, notifications, announcements, policy changes, events, accomplishments, records, ideas, best practices, etc.
  • 56. citoolkit.com Area Boards Remember that status visuals are used to display the status of projects, processes, production, productivity and performance. Visual Management 56 Area Boards STATUS Performance metrics Kaizen progress Ideas & projects Andon lights Benchmark & best practices PERFORMANCE PRODUCTION PROJECTS PERFORMANCE PROJECTS
  • 57. citoolkit.com Area Boards Area information boards can be used to display . . . Visual Management 57 Area Boards Benchmark information Kaizen progress Best practices and lessons learned Operational records The status of improvement projects Other teamwork activities
  • 58. citoolkit.com Performance Metrics 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. Visual Management 58 Metrics Performance metrics should be displayed in a visually appealing way to allow people to get insight into how the operation is performing.
  • 59. citoolkit.com Performance Metrics Benefits of Visual Performance Boards . . . Visual Management 59 Metrics Presents the performance of a team, department, process & business Directs the team discussions around priority areas Creates a sense of purpose and drives motivation Serves as a communication tool for others outside of the team
  • 60. citoolkit.com Performance Metrics Customized performance charts allow to compare actual performance against target. Visual Management 60 Metrics This can be shown on daily, weekly, monthly or quarterly basis
  • 61. citoolkit.com Performance Metrics Performance information should be meaningful, easy to understand, free of technical terms, accurate and up-to-date. Visual Management 61 Metrics Everyone must be able to understand the message. Keep them as simple as possible.
  • 62. citoolkit.com Performance Metrics 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. Visual Management 62 Metrics
  • 63. citoolkit.com Performance Metrics Production Summary Boards are used to monitor the output of an operation and see if it meets customer demand. Visual Management 63 Metrics They may also display other information such as efficiency, Takt time, etc.
  • 64. citoolkit.com Performance Metrics Production summary boards should be visible in the workplace, and everyone should be able to see where production stands. Visual Management 64 Metrics This allows production and maintenance teams to quickly resolve process issues that may occur during production.
  • 65. citoolkit.com Performance Metrics Process-related metrics need to be displayed near the machine or work cell. Visual Management 65 Metrics While general plant metrics need to be posted in a central location where everyone can see it easily.
  • 66. citoolkit.com Andon Lights Andon lights are powerful visual tools which are installed on production machines to indicate their current status. Visual Management 66 Andon Since they are visible from a distance, they are very useful in bringing immediate attention to problems as soon as they arise.
  • 67. citoolkit.com Andon Lights For example, a light may turn on to indicate a shortage of raw materials, awaiting parts, or the need for maintenance. Visual Management 67 Andon The system can include means to stop the process, so the issue get resolved.
  • 68. citoolkit.com Andon Lights Each color represents a particular state of the machine or production line. Visual Management 68 Andon Operation is normal Operation is down (no order, maintenance, cleaning, quality checks, etc.) Operation is down for unknown reasons and needs further investigation
  • 69. citoolkit.com Tips to Create an Effective Visual Management System Visual Management 69 Use the colors and standards that are being used consistently Let the teams help creating the visual controls and boards Decide where you need to implement visual management Determine the type of information that needs to be conveyed Decide who are your target audience Create a guide that describes the key elements associated with the visual management system Remember that your goal is to make the area more informative Decide who are going to be involved in the implementation effort Mark floors, add signs, label storage areas, post standard work, create visual boards, etc. Include reviewing the visual controls in your Gemba walks Design and use a checklist to evaluate your visual controls
  • 70. citoolkit.com Tips to Create an Effective Visual Management System An effective visual management system . . . Visual Management 70 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
  • 71. citoolkit.com Summary Visual management is not just making charts and metrics visible on a wall! Visual Management 71 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
  • 72. citoolkit.com 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. Visual Management 72 For example, organizing the workplace using 5S, stabilizing how work is performed using standard work, or stabilizing equipment performance and reliability using TPM.
  • 73. citoolkit.com Further Information Visual management is a collaborative process, and people engagement is key to the contribution they will provide later. Visual Management 73 Listen to people, involve them, and let them own the visuals.
  • 74. citoolkit.com 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. Visual Management 74
  • 75. citoolkit.com Further Information Visual management can also be useful for support functions in the production environment (such as accounting, sales, engineering and R&D) and in the service sector. Visual Management 75
  • 76. citoolkit.com Further Information Examples in the Service Sector . . . Visual Management 76 The queue counter display in a bank A sign indicating the different types of waste disposal bins in a hotel lobby A sign indicating cleaning in progress or wet floor in a washroom in a shopping mall The signs in an airport that direct passengers to the luggage claim area
  • 77. citoolkit.com Further Information A Kanban provides a visual method of inventory control and uses color- coded cards to support a pull system. Visual Management 77 DOING TO DO DONE PROGRESS TRACKING BOARD
  • 78. citoolkit.com Examples of How to Eliminate Waste using Visual Management Visual Management 78 Minimize the non-use of skills by visually sharing problems and working together to solve them. Eliminate excess inventory by improving visibility of storage. Reduce motion by ensuring all parts and tools are accessible and recognizable. Eliminate excess inventory by improving visibility of storage. Reduce defects by quickly responding to Andon signals. Prevent overproduction by visually displaying production actuals and targets. Prevent excess transportation by labeling and marking locations and paths. Reduce waiting by visually defining work sequence.
  • 79. citoolkit.com Example from a Production Environment Visual Management 79 2 Andon lights 1 Safety sign 4 Machine identity 3 Floor marking 5 Visual instructions 6 Gauge marking
  • 80. citoolkit.com Kamishibai Board A Kamishibai board is a visual management method that is used to manage routine activities in a workplace. It can be used to audit safety and security measures as well as to confirm that standard work is being undertaken by all employees. Visual Management 80 In its simplest form, it consists of a board and multiple cards that displays selected activities to be performed.
  • 81. citoolkit.com Kamishibai Board Typically, each card is red on one side and green on the other to indicate whether the activity has been completed or not. Visual Management 81 WEEKLY DAILY
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