Transcript Lean Event Overview

Visual Management
Quick Review
What Comes to Mind When You See This?
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Definition
Visual Management is the use of controls that
will enable an individual to immediately
recognize the standard and any deviation
from it.
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Self Explaining
Self Cleaning
Self Regulating
Self Improving
Visual Management
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Visual Management is used to ensure that:
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There is nothing extra
The environment is immaculate, safe, and self-cleaning
Standards are easy to recognize and abnormal conditions are
easier to correct
Performance and progress are readily apparent
Zero Defects is a reality!
In a visually managed workplace anyone will know
the who, what, where, when, why and how of an
area within 5 minutes
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Why Visual Management ?
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Increase Safety
Enhance Quality
Reduce searching time
Increase job satisfaction
Eliminates many
frustrations
Improve communication
Six Levels of Visual Management
6.
ErrorProof
(defect free)
5. Prevent defects
from moving on
in the process.
4. Warn of abnormalities
(built-in alarm).
Visual Control,
levels 3-6, prevent
defects and errors:
• metrics/status board
• error prevention boards
• Andon lights
3. Build standards into the workplace.
2. Share standards at the site.
1. Share information.
Workplace
organization
and
standardization.
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Visual Displays,
levels 1 and 2,
share information:
• signboards
• demarcations
• std instructions
5S workplace organization:
Sort, Store, Systematic Cleaning, Standardize, Sustain
How Do We Implement Visual Management?
• Start with the foundation
- 5S (work place organization)
• Build the second level
- Visual Displays (communication)
• Build the third level
- Visual Controls (control the standard)
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The 5S’s Are:
Seiri - (Sort)
Seiton - (Simplified Storage)
Seiso - (Shine)
Seketsu - (Standardize)
Shitsuke - (Sustain)
A Set Of Agreements Made By The Natural Work Team
Concerning Work Place Organization
The agreements will govern
work group operations.
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The Benefits Of 5S
5S provides a basis for being a world-class competitor and
the foundation for a disciplined approach to the workplace.
• Safer working conditions
• A cleaner and more organized work area.
• Quality Improvement – a standard way to do things
• Reduction in non-value added time.
• Effective work practices and processes.
• 5S visually demonstrates that change is happening.
• It’s quick, makes an immediate positive impact, and can be fun.
• 5S facilitates change towards a culture of continuous improvement.
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Review: 5S Levels Of Achievement
LEVEL
5
Continuous
Improvement
LEVEL
4
Focus On
Reliability
LEVEL
3
Make It
Visual
LEVEL
2
Focus On
Basics
LEVEL
1
Just
Beginning
Cleanliness problem
areas are identified
and mess prevention
actions are in place.
Needed items can
be retrieved in 30
seconds with
minimum steps.
Potential problems
are identified and
countermeasures
documented.
Proven methods for
area arrangement
and practices are
shared and used.
Root causes are
eliminated and
improvement actions
include prevention.
Cleaning schedules
and responsibilities
are documented
and followed.
Minimal needed
items arranged in
manner based on
retrieval frequency.
Work area cleaning,
inspection, and
supply restocking
done daily.
Proven methods for
area arrangement
and practices are
used in the area.
Sources, frequency
of problems are
noted w/ root cause
& corrective action.
Initial cleaning is
done and mess
sources are known
and corrected.
Needed items are
outlined, dedicated
locations are labelled
in planned quantities.
Visual controls and
indicators are set
and marked for
work area.
Agreements on
labelling, quantities,
and controls are
documented.
Work group is
routinely checking
area to maintain
5-S agreements.
Necessary and unnecessary items are
identified; those not
needed are gone.
Needed items are
safely stored and
organized according
to usage frequency.
Key area items
are marked to check
and required level of
performance noted.
Work group has
documented area
arrangement and
controls.
Initial 5-S level
is established and
and is posted in
the area.
Needed and not
needed items are
mixed throughout
the area.
Items are randomly
placed throughout
the workplace.
Key area items
checked are not
identified and are
unmarked.
Work area methods
are not always
followed and are
not documented.
Work area checks
are randomly done
and there is no
5-S measurement.
Sorting
Simplifying
System Clean
Standardize
Sustaining
Implementation: First by Row
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Then
by
Column
Sorting
Separate the necessary from the unnecessary.
• Identify what is required to work a process or perform
a particular operation or task.
• Remove unnecessary tools, equipment, files, binders, parts,
procedures, furniture, and other ‘stuff’ from the area.
Easing access to necessary items by
eliminating the unnecessary.
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Simplified Storage
Store It: Create a place for everything.
SIMPLFY • Organize materials according to frequency of use.
• Implement visual aids to improve communication.
A place for everything and everything in place.
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Shine (Systematic Cleaning)
Perform daily cleaning and inspection of area
and equipment to determine status and need
for corrective and preventive action.
• Decide how to make multiple-shift decisions.
• Plan how to coordinate and communicate with other areas.
• Identify key points to check to ensure proper performance.
• Determine acceptable performance.
• Determine corresponding visual indicators and controls.
• Mark equipment and controls.
• Establish ‘who and when’ cleaning plan.
• Conduct daily cleaning and inspections.
A process developed and used by the team.
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Standardize
Determining, sharing, and using the best
processes and methods.
• Document present work area agreement and routine checks.
• Share the standard method across similar work areas.
• Document new standard methods as improvements are made.
• Review standardization activities, logistics, and support.
Standardization serves to minimize variation and
the effect of variation on quality and speed
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Sustain
Keeping the gains and building further progress.
• Determine the 5S level of achievement.
• Perform routine checks.
• Analyze results of routine checks.
• Measure progress and plan for continuous improvement.
•Review the planned activities of sustaining.
Pride in improvement, accomplishments,
and the desire to do more.
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A Place For Everything
At a glance: “Do I have the tools and equipment to
do my job?”
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No Room For Chaos
Organizing the work station supports standard work.
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Six Levels Of The Visual Business
6.
ErrorProof
(defect free)
5. Prevent defects
from moving on
in the process.
4. Warn of abnormalities
(built-in alarm).
Visual Control,
levels 3-6, prevent
defects and errors:
• metrics/status board
• error prevention boards
• Andon lights
3. Build standards into the workplace.
2. Share standards at the site.
1. Share information.
Workplace
organization
and
standardization.
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5S workplace organization:
Sort, Store, Systematic Cleaning, Standardize, Sustain
Visual Displays,
levels 1 and 2,
share information:
• signboards
• demarcations
• std instructions
Visual Displays
• Visual displays share information and / or standards
• Show how to do the job (standard, agreed-upon best practice).
• Show how things are used.
• Show where things are stored.
• Show performance status.
• Identify hazardous areas
Visual Displays Communicate
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Visual Controls
• Visual Controls build standards into the workplace and warn,
stop or prevent abnormalities
• Control inventory levels.
• Indicate when people need help.
• Mistake-proof the operation.
Visual Controls Control
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Types Of Visual Displays and Controls
Examples :
A: Passively shares information by indicating or telling.
stop
sign
B: Sends information by first catching attention.
alarm
clock
C: Sends information and limits responses.
speed
bump
D: Ensures the right thing will happen.
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different-size
mail slots, etc
Visual Management
Quick Review