Transcript Slide 1

P3 – VISUAL MANAGEMENT
INTRODUCTION
1. Provide real-time information on work
place status by a combination of simple,
effective visual information aids that allow
employees to understand their influence
on the organization overall performance
hence allowing the employees to improve
their performance.
P3 – VISUAL MANAGEMENT
OBJECTIVE
1. Expose waste so that it can be eliminated and prevented from recurring
making the workplace more efficient.
2. Make abnormalities in the 4Ms (Man, Machine, Material, Method) process
inputs visible to everyone for prompt corrective action.
3. Enable trends in QCDMS & abnormalities to be visible for timely preventive
action to be taken.
4. Motivates everybody to improve by clarifying key performance targets.
5. Makes operation standards quicker and easier to understand by all
employees so they can follow them.
6. Builds participation through shared information.
7. Creates flow in the value stream and allows pull to the voice of the
customer.
P3 – VISUAL MANAGEMENT
9 VISUAL MANAGEMENT AREAS
Quality
Delivery
Cost
S.H.E
MAN
KPIs
MACHINE
MATERIAL
METHODS
MAKE ABNORMALITIES &
STATUS VISIBLE
P3 – VISUAL MANAGEMENT
PRINCIPLES OF VISUAL MANAGEMENT
SAFETY
VISUAL
FACTORY
PRODUCTIVITY
QUALITY
Hazards Visual Recognition
Safe Areas Visual Display
5S Eliminates Workplace Clutter
Awareness of Safety Measures
Associates Works Progress
Production Rate
Progress Towards Goals
Production Status
Efficient Operators
Operator Prompts for Error Proofing
Clearly Marked Tools Reduce Errors
Visible Calls to Support Personnel for Parts
Shortage / Problems
Reduce Rework
Immediate Indication of Out of Tolerance
Variables
P3 – VISUAL MANAGEMENT
VISUAL MANAGEMENT INITIATIVES
1. Visual Control Boards.
2. Andon
3. Footprints
4. Signage
5. Obeya
4. Hansei
P3 – VISUAL MANAGEMENT
VISUAL BOARD
What is Visual Control Board
1. A color-coded , physical visual control system used for monitoring of shop-floor activities
and KPIs.
Use of Visual Control Board
1.
2.
3.
4.
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
1. It quickly gives visibility to the progress of each tasks for further action.
2. Identifies the resources and activities being undertaken.
P2 – VISUAL MANAGEMENT
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 goods
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 section.
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.
This is an example of a pull board that could be used with internal operations, as shown, or even
with external customers.
P3 – VISUAL MANAGEMENT
ANDON
What is Andon
1. 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.
2. It can be used manually or automatically.
3. It also one of the principle elements of the Jidoka
quality-control method.
P3 – VISUAL MANAGEMENT
ANDON
Use of Andon
1. Alerts management and other workers to quality or
process problem.
2. Gives the worker the ability to stop production when a
defect is found, and immediately call for assistance.
3. Indicates where the alert was generated, and may also
provide a description of the trouble whether shortage of
material or maintenance call or supervisor call.
.
P3 – VISUAL MANAGEMENT
ANDON
Defect created or found
Common reasons
for manual
activation of the
Andon
Part shortage
Equipment/Tool malfunction
A safety problem exists
P3 – VISUAL MANAGEMENT
ANDON
Benefits of Andon
1. Reduces operation & maintenance costs by identifying problems before they become
major issues.
2. Increases equipment availability by making downtime issues more visible, thus
prompting immediate rectification to the issues.
3. Supports Jidoka implementation by making the problem status visual.
Mechanism of Andon
Abnormality
Andon Indicator
Response from
support team
P3 – VISUAL MANAGEMENT
ANDON
Types of Andon
1
Visual Andon
Graphics
Text
Coded signal lights
Green - no problems
 Ideal for STOP /
WAIT / GO signaling
in busy factories
 Boost health and
safety.
 Display production data in
real time.
 Calculate shift efficiencies
and production targets.
2
Yellow - situation requires
attention, production flow at risk
Red - PRODUCTION STOPPAGE:
IMMEDIATE ASSISTANCE
REQUIRED
Audio Andon
Coded
Tones
Coded
Tunes
Buzzers /
Alarms
Prerecorded
Messages
P3 – VISUAL MANAGEMENT
FOOTPRINT
What is Footprint
1. Markings on the floor or work area outlining specifically where items should be placed.
Benefit
1. To ease employees during storage or retrieval.
2. It avoids employees wasting time looking for things or pondering their next move.
3. The workplace becomes clean and better organized.
4. Operation on the shop floor and office become easier and safer
 .
5. Visible location of parts or equipment for easy traceability and save time of searching
P3 – VISUAL MANAGEMENT
FOOTPRINT
CREATING FOOTPRINT
1. A footprint is an outline of the items required at work areas indicating where the items
should be placed.
2. Rules about footprints or floor borders
a) Mark from the floor up to workbenches etc
b) Start with plastic tape to test out, then move to paint
c) Use colours to code footprints as shown in the following example, as a guideline :
Light Blue - Raw parts/material
Black - Finished good/parts
Red - Non-conforming/KIV parts/material
White - Other than parts/material
Yellow – Border of work area
P3 – VISUAL MANAGEMENT
FOOTPRINT
Yellow for work area border
Black for finished part
Light blue for raw material
LINE
SOZAI
5S CORNER
KANSEI
TOOL CABINET
NG
QC CORNER
Red for non-conforming part
White for equipment
VISUAL BOARD
P3 – VISUAL MANAGEMENT
SIGNAGE
Signage is any kind of graphics created to display information.
Two types of signage
1. Displays
 A visual display relates information and data to employees in the area. For example, charts showing
the monthly revenues of the company or a graphic depicting a certain type of quality issue that group
members should be aware of.
2. Controls
 A visual control is intended to actually control or guide the action of the group members. Examples of
controls are: stop signs at intersections, handicap parking signs, or no smoking signs.
Figure 8.0
P3 – VISUAL MANAGEMENT
SIGNAGE
Signage must be used appropriately for
providing pertinent information on:
• hazardous and risky areas & installation
• materials
• safety measures
• emergency exits, etc.
Signage shall be:
• in accordance with international
standards, code of practice
• maintained
• up-to-date
• be well known to, and easily understood
by employees, visitors and the general
public as appropriate
• visible from at least 1.5m and easily seen
by forklift driver
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STANDARDISATION
PRODUCTION LEVELLING
FLEXIBILITY
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8
3 VISUAL MANAGEMENT
2 TOTAL EMPLOYEE INVOLVEMENT & DEVELOPMENT
1
LONG TERM BUSINESS THINKING
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QUALITY RIGHT 1ST TIME EVERY
TIME
5
WASTE ELIMINATION
PULL SYSTEM
AMS 9 PRINCIPLES
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