This document discusses visual management and its importance in operational excellence. It defines visual management as using visual displays, metrics, and controls to communicate information instead of using text. The objectives of visual management are outlined, including supporting safety culture, continuous improvement, and making standards visible. Common visual tools like Andon boards, error-proofing, standard work charts, and OEE boards are described. The document also categorizes visual management into visual displays, metrics, and controls and provides examples of each. Finally, it emphasizes that visual management should align with overall lean management systems to establish continuous flow and reinforce standards.

1. © Lean & Mean Consulting. All rights reserved. 2015
07/ 16
Visual Management
 Visual Controls
 Visual Displays
 Visual Metrics
World-Class Standards of Operational Excellence

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Learning Objectives
1. Appreciate how Visual Management supports the Zero Injury
Safety Culture
2. Understand that Visual Management is an integral part of the
Continuous Improvement transformation
3. Become familiar with common visual tools such as Andon,
Red Tagging, MOS boards, Kanban, error-proofing, standard
work, OEE boards, etc.
4. Gain knowledge on how to apply visual tools to add structure
and stability to operations, reducing variation and increasing
efficiency

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 Introduction
 5S - The foundation for a
visual workplace
 Types of visual
management
 Visual display
 Visual metrics
 Visual control
Contents
 Common visual tools
 Activity Boards
 MOS, OEE,
 Hourly attainment
 Standard work
 Kanban

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Visual Controls / Visual Metrics / Visual Displays
Module. 07

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What is Visual Management
 Visual Management enhances the smooth flow of information by using
visual and audio signals instead of texts or other written instructions
 Visual Management is the concept of making a workplace safe and more
effective by making the current condition of a workplace obvious at a
glance
 Visual Management includes a set of techniques that makes operation
standards visible so that people can follow them more easily
 These techniques expose waste so that it can be prevented and
eliminated

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The name given to a whole range of activities for communicating
and controlling what needs to be done.
What is this?
Fundamentals of Gemba House
Visual Management
Visual Management

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Fundamentals of Gemba House
Visual Management
Visual Management allows us to:
• See abnormal conditions as soon as they occur.
• Tell at a glance how we are doing.

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• Safety & Health Information
• Identification of people, places and objects
• Procedures and methods of work
• Quality standards, instructions, results
• Status visibility
• Problem visibility
• Scheduling
• Communication
Types of Visual Management

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Visual Controls
9
EVERYDAY
VISUAL CONTROLS

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5 Disciplines for a Successful Visual
Management System
Disciplines Description
Project
identification
• Define implementation areas and establish current
conditions and baselines
Workplace organization • Implement 6S as a strong foundation
Visual display • Create a visual communication system providing the right
information in the right format at the point of need
Visual metrics • Quantify the path to targets for success
Visual control • Create an error-proofed environment to promote easy
adherence to standards

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 5S workplace organization
can be enhanced by the use
of visual tools
 Visual tools help you to
monitor results and look for
things easily and quickly
Creating a Visual Workplace
Note: Visual management IS NOT decoration !

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3 Types of Visual Management
• Label to make it perfectly clear where
things belong and what the procedures are
• Shadow boards, boundary samples
Visual Display
• Quantify the path to targets for success
• OEE Boards, MOS Boards, Attainment
Boards
Visual Metrics
• Create an error-proofed environment to
promote easy adherence to standards
• Poke Yoke, Red Rabbits
Visual Controls

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Visual Displays
 Make it clear when something is out of place or
missing
 Labeling is mandatory to make it obvious where
things belong
 Labels are for everyone: those working in the area,
those that are new to the area, and those that might
need to know things about the area.

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Examples of Visual Display
Floor markings
Bin labels for different components
Scheduling
Labels to identify documentation locations
Temporary work station or activity

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 Andon refers to any visual display that
shows status information
 Andon is the Japanese word for paper
lantern
 Serves as warning system to signal and
identify problems in the process
What is an Andon?

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Andon Examples
4 Function andon system
Warning sensors linked to andon
and/or audio device
Andon escalation process

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Visual Metrics
 Allow everyone to “know the score” and they make out-of-
standard situations immediately obvious
 Enables everyone to ‘see’ how we’re performing
 Helps highlight problems, or variances from standard
 Encourages employee involvement and open discussions
 Facilitates the communication and identification of areas that
need improvement

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• Gaps? Trends?What is
happening?
• Root causes?Why?
• Correct the problem –
implement containment
action?
• Prevent the problem –
permanent corrective action?
What needs to
be done?
• Who does what?
• Any support needed?
Who is going to
do it?
• Prioritization?
• Deadline?
• Milestones?
When is it going
to be done?
Example of Visual Metrics
Manufacturing Operating System (MOS)
Visual Metrics provide a mechanism to
take action…

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 Create an error-proofed environment
 Promote easy adherence to standards
 Display goals and targets
 Are simple devices or visual standards to help prevent
mistakes
 Make it easy to find things
Visual Controls

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Examples of Visual Control
E-stopLabeling of disposal bins Requirements
Lock out procedure Stop before proceeding
Shadow Board

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 Error-proofing refers to
techniques that make it
impossible to make mistakes
 Also known as Poka Yoke
 Error-proofing helps people
and processes work right the
first time
Error-proofing

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Error-Proofing Has Dual Focus
DefectsMistakesProcess
Prevention
Poka-Yoke that focuses here works
on mistake prevention or making
mistakes impossible.
Detection
Poka-Yoke that focuses here
works on mistake detection, or
making sure mistakes do not turn
into defects.
People and systems do make mistakes.
A portion of mistakes turn into defects.

23. Visual Controls / Visual Metrics / Visual Displays
Module. 07

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What is an Activity Board?
 Activity board is a visual tool to guide teams to action
 It is a visual scorecard for the team’s progress toward
company, departmental and team visions and targets
 It keeps everyone’s attention on the project, using colors and
graphs to make information clear to everyone who sees it
 Is a focal point for team meetings, and a place for
management’s feedback and encouragement
Key TPM Tools

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MOS Board OEE Board
Post the applicable schedule at each activity
board so it is clear:
• when the meetings occur
• who needs to be present
• what information will be reviewed
Examples of Activity Boards

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Example of Hourly Attainment Board
HOURLY ATTAINMENT BOARD Line X

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 Visual management is an essential part of a Lean
management system
 Visual management uses displays, metrics and controls
to help establish and maintain continuous flow
 Visual tools reinforce standards, and help people detect
abnormalities at a glance
 For visual management be effective and sustainable, it
has to be integrated and align with management
standard work - MOS, OEE, BP – the way we manage the
business
Summary

28. 28© Lean & Mean Consulting. All rights reserved. 2016