The goal of visual management is to translate shop floor processes and production statuses into easy-to-understand visual overviews. Think of it as manufacturing's scoreboard. With one glance, the whole team can get an understanding of a factory's performance

1. Visual Management
Improving Plant Reliability Through
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2. Visual Management
 Visual management is the display of information in the workplace to inform teams, enforce work standards, and highlight or
prevent problems. There are many ways to use visual management, and this concept is deeply embedded in Lean thinking
 Visual management system is designed to create a visual workplace – a work environment that is self- explaining, self-ordering,
self-improving. A good 5S condition is a clean, well-ordered workplace that is the foundation of improvement.
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3. Visual Management
 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
 The aim is to enable anyone working In the
workplace to be 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
 Employees need visuals that show what is
expected from them and to keep them informed
about production status and other goals
 Visual Management Can also be used to share
goals and ideas, indicate safety risks, promote
safe behaviors at work, and to report and
kaizen progress.
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4. Visual Management
 Lean Organization rely heavily on visual
management to defect 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
 A Good Illustration of visual management are
road signs, just as road sings are easier to
understand than written signs, workplace
visuals are easier to understand than written
instructions, 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.
 Therefore, effective workplace visuals can have
positive impact on Productivity, Safety, Quality.
And on- time delivery.
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5. Visual Management Benefits
1. Improved Safety and Ergonomics
2. Continuous Improvement
3. Sets a Baseline for Standard work
4. Less Defects
5. Satisfy Consumer Demand
6. Quick Changeover and Less Downtime
7.Create Workflow
8. Reduce Waste ad Improve Productivity
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6. Visual Management
Two Tools of visual Management
Displays
 To make staff aware of related data and
information
 Charts, graphs etc.
Controls
 To guide the action of staff members
 Sign boards, do’s and don’ts signs
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7. Phase of Visual Management
4. Visual Control
2. Visual Display
3. Visual Measures
1. Workplace Organization
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8. 1. Workplace Organization
 WPO is a vital link to continuous improvement
and combination of both 5S and Visual
Management
 It Would be very difficult to improve and implement
lean manufacturing principles such as quick
changeover. Low inventories. FIFO, JIT, and many
more, Without workplace organization.
 The 5S’s are an important part of the Workplace
organization process
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9. 2. Visual Display
 It is a method to visually communicate important
information in the workplace. It contain information
regarding safety, Quality, Operations, Equipment, Work
Environment, Progress /achievements.
• Benefits:-
 Make work safer and easier
 Communication information about performance
 Makes standards visible
 Makes Problems recognizable
 Creates a shared knowledge base
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10. 3. Visual Measures
 Visual measures indicator of performance
measurement that allow everyone to know the score
and help them to track the work
 In this, Company uses some standard measurement
tools and indicators to track the activity and goals like
 Changeover Clock
 Downtime Clock
 Production Counters
 Process Capability Logo
 Error Proof Symbols
 Bottleneck Symbols
 P.I. Indicator
 Current Part Running
 Lost Time Accidents
 Limbo Bars
 5S Audit
 BOS Charts
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11. 4. Visual Control
 Visual Controls are any device or symbol that effectively
places information at the point of use which create a
mistake - proofed environment to Promote easy
adherence to standards
 Followings are some tools to use in visual control :-
 Indicators
 Labels
 Meters
 Scales
 Lights
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12. Process For Development of Visual Workplace
Input
Confirm &
share clear
understanding
of customer
needs
Confirm
optimum
process to add
value, add &
ensure flow
Identify
information
needed by
staff to operate
an effective &
efficient
process
Identify most
appropriate
tools to
maximize
visual
management
Apply tools
and review
value with staff
Out put
(workplace)
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13. Visual Management Tools
Visual control
boards
Andon
Footprints Red tagging
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14. 1. Visual Board
 A color –coded, Physical visual control system used for
monitoring of shop- floor activities and KPIs.
 Use of Visual Control board:-
 Visual boards are used as activators and data communication
centre.
 The visual board area is used for shop-floor meetings.
 A centre of periodical progress reviews and updates.
 Used to drive the business processes from the boardroom to the
shop floor
 Benefits of visual control board:
 It quickly gives visibility to the progress of each tasks for further
action
 Identifies the resources and activities being undertaken
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15. 1. Visual Board
 Red zone indicates the supplier is on the verge of not
satisfying their customer. Very low level of goods
maintained
 Yellow zone indicates customer requirements are being
met. Low level of finished good maintained
 Green zone indicates the customer’s needs are being
fulfilled. Supplier is building more than the customer is
requiring and it may be time to stop production until
demand is more in line with supply
 Other pertinent information (e.g. Quality performance)
would be contained in the information
 The Cards hanging on the hooks in the colored zones
reflect the part number identified in the section, a given
quantity of material in one container. When a card is on
the hook it indicates an empty container
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16. 2. Andon
 Andon (Japanese for lantern) is a tool for visual
management and refers to a system of signals used to
indicate the operational status (at a glance) of a
machine or work center.
• Benefits
 Reduces operation & maintenance costs by identifying
problems before they become major issues.
 Increases equipment availability by making downtime issues
more visible, thus prompting immediate rectification to the
issues.
 Supports jidoka implementation by making the problem status
visual
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17. 2. Andon
Andon
Text
 -Display production data in
real time.
 -Calculate shift efficiencies
and production targets
Graphics
-Ideal for stop/wait/go signaling in busy
factories
-Boost health and safety
Coded signal lights
-Green- No problem
-Yellow- Situation requires attention production flow at risk
-Red – Production stoppage immediate assistance required
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18. 3. Footprints
 It is a markings on the floor or work area outlining
specifically where items should be placed .
• Benefits
 To ease employees during storage or retrieval
 It avoids employees wasting time looking for things or pondering
their next move.
 The workplace becomes clean and better organized.
 Operation on the shop floor and office become easier and safer,
 Visible location of parts or equipment for easy traceability and
save time of searching
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19. 3. Footprints
Light Blue for
raw material White for equipment
Black for
finished part
Red for non-
conforming
part
Yellow for work area border
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20. 4. Tagging
 Tagging is a method that involves placing tags on items
to designate their status
 It us used to identify unnecessary items that need ti be
either thrown out, recycled, sold or relocated.
 They are especially useful as a visual management tool
as they easily communicate visually to other staff
members that the tagged items are unneeded/
unwanted
 5S short event :- red tagging on items which are
unwanted or to be removed see the pic.
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21. 4. Tagging
 Above :- Tagging (common called ‘FUGUAI
Tagging’) of production equipment during initial
cleaning in TPM activities
 Below :- Tag is removed only after repair is made
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22. Floor Color Coding Standards
 These Colors are widely accepted and comply with international standard
Aisle ways and traffic lanes
Scrap, Rework and Red tag
Material or product held for inspection
Raw materials Work in Progress
Finished Goods
Areas to be kept clear for safety reasons Physical and health risk areas
Areas to be kept clear for operational
reasons
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23. Example
 Pipe Marking and Color Coding Standards
 Pipe marking communicates all the necessary information about the pipeline in workplace.
 Arrows are used to indicate the flow direction while colors often indicate the nature of the content
 You may also post the labels on the pipelines
 These colors are widely accepted and comply with international standards
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24. Example
 Colored sleeves can be used to identify all the tools within a particular kit and team area. This will help
reducing the time spent looking for lost tools
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25. Example
 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.
 It is recommended to post Visual work- related
instructions trouble logs at every machine
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26. Example
 Making gauges, oil levels and lube points are examples
of visual controls that enable employees to easily defect
abnormalities and out of specification condition
 Color coding can be applied to gauges and other
measuring devises to visually monitor whether
process parameters remain within acceptable or
safe ranges
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27. Meetings
 Daily meetings can be conducted in front of the board
to discuss the previous day’s issues and plan for the
work ahead
 Reviewing the board regularly is very important for the
meeting to be productive. Data should be collected on a
daily basis to update the board
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28.  Visual management is a Collaborative process, and people engagement is key to the contribution they will provide
later. Listen to them, and let them own the visuals
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29. Thank you for listening !
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