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Visual Management
 Visual Controls
 Visual Displays
 Visual Metrics

World-Class Standards of Operational Excellence

© Lean & Mean Consulting. All rights reserved. 2015
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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Contents

 Introduction  Common visual tools

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

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Module. 07

Visual Controls / Visual Metrics / Visual Displays

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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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 Fundamentals of Gemba House
Visual Management
Visual Management

What is this?

The name given to a whole range of activities for communicating

and controlling what needs to be done.

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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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Types of Visual Management

• Safety & Health Information

• Identification of people, places and objects
• Procedures and methods of work
• Quality standards, instructions, results
• Status visibility
• Problem visibility
• Scheduling
• Communication

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Visual Controls
EVERYDAY
VISUAL CONTROLS

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5 Disciplines for a Successful Visual
Management System

Disciplines Description
Project • Define implementation areas and establish current
identification 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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Creating a Visual Workplace

 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

Note: Visual management IS NOT decoration !

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3 Types of Visual Management

• Label to make it perfectly clear where

Visual Display things belong and what the procedures are
• Shadow boards, boundary samples

• Quantify the path to targets for success

Visual Metrics • OEE Boards, MOS Boards, Attainment
Boards

• Create an error-proofed environment to

Visual Controls promote easy adherence to standards
• Poke Yoke, Red Rabbits

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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

Temporary work station or activity

Scheduling

Labels to identify documentation locations

Bin labels for different components

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What is an Andon?

 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

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Andon Examples

Warning sensors linked to andon

and/or audio device

4 Function andon system

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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 Example of Visual Metrics
Visual Metrics provide a mechanism to
take action…

Manufacturing Operating System (MOS) What is • Gaps? Trends?

happening?

Why? • Root causes?

• Correct the problem –

What needs to implement containment
be done? action?
• Prevent the problem –
permanent corrective action?

Who is going to • Who does what?

do it? • Any support needed?

• Prioritization?
When is it going
• Deadline?
to be done?
• Milestones?

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Visual Controls

 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

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Examples of Visual Control

Labeling of disposal bins E-stop Requirements

Lock out procedure Stop before proceeding

Shadow Board
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Error-proofing

 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

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 Error-Proofing Has Dual Focus

People and systems do make mistakes.

A portion of mistakes turn into defects.

Prevention
Poka-Yoke that focuses here works
on mistake prevention or making
mistakes impossible.

Process Mistakes Defects

Detection
Poka-Yoke that focuses here
works on mistake detection, or
making sure mistakes do not turn
into defects.

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Module. 07

Visual Controls / Visual Metrics / Visual Displays

 Key TPM Tools
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

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 Examples of Activity Boards
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

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Example of Hourly Attainment Board

HOURLY ATTAINMENT BOARD Line X

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Summary

 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

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© Lean & Mean Consulting. All rights reserved. 2016
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