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Visual Management

Visual management is a set of techniques that

1) Expose waste so you can eliminate it and prevent it from recurring in the future,
2) Make your companys operation standards known to all employees so they can easily follow them, and 3) Improve workplace efficiency through organization.
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V M Steps
Organizing your workplace by using a method known as the 5 S's (sort, shine, set in order, standardize, and sustain)

Ensuring that all your required work standards and related information are displayed in the workplace

Controlling all your workplace processes by exposing and stopping errorsand preventing them in the future

V M What it does
Improve the "first-time-through" quality of your products or services by creating an environment that: Prevents most errors and defects before they occur. Detects the errors and defects that do occur and enables rapid response and CA. Establishes and maintains standards for zero errors, defects, and waste.
Improve workplace safety and employee health by: Removing hazards. Improving communication by sharing information openly Creating compliance with all work standards, reporting deviations, and responding quickly to problems.

Improve the overall efficiency of your workplace and equipment, enabling your organization to meet customer expectations.

V M Areas to focus
You can effectively gain control over your company's manufacturing or business processes by focusing on the following areas

Value-added activities (Work process and methods of operation) Information sharing Source, in-process and outgoing inspections Material quantities and flow (Storage, inventory and supplies) Health and safety
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V M Start activities
Train all involved employees about the visual management techniques

Create storage ("red tag") areas for holding materials you will remove

Arrange for tags, cleaning materials, paint, labels, marking tape, and sign materials.

Make sure that all employees understand and follow your company's safety regulations and procedures as they make changes

Steps for 5S-SORT


Goal is to keep what is needed and remove everything else

Reduce the number of items in your immediate work area to just what you actually need

Find another storage area for all supplies that you need but do not use every day

Decide how you will prevent the accumulation of unnecessary items in the future

Tie red tags to all the items you remove from your work area. Place the items in a temporary "red-tag storage" area for five days

After five days, move any item that you haven't needed to a central red -tag storage area for another 30 days Use a logbook to track what you do with all red-tag items

Categorising things being used and not used


Can be Used
Sufficient functions, Sufficient period, Sufficient amount Insufficient functions, insufficient period, insufficient amount

Things

Cannot be used

Unlikely to be used

Prefer not to use Seems unnecessary

Inventory organisation system


Use frequency Description Organisation Method
Cannot be used or Unlikely to be used Inventory items Rarely used

Defective goods and dead inventory that will not be used


Used twice a year

Discard

Remove from factory and store else-where Store near Operation Where used Keep close at hand at all times

Can be used

Occasionally used

Used once every one or to months

Often Used

Used every hour or every day

Sorting Criteria Chart


Frequency of use Action Never(unneeded) Throw away Once a year Place in Storage <one month Store in factory/office Once a week Store in general work area Once a day or more Carry or keep at workstation

Red Tag Information


Item Name Quantity ID Value Date tagged with reason Dept., Shift, Operator Disposal method Red-tag holding area log-in date Holding area removal-disposal date

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Steps for 5S-SHINE


Clean your workplace by eliminating all forms of contamination, including dirt, dust, fluids, and other debris

Cleaning is also a good time to inspect your equipment to look for abnormal wear or conditions that might lead to equipment failure

Keeping equipment clean and "shiny" should be a part of your maintenance process Teach the concepts of " cleaning as inspection" and "eliminating sources of contamination."

Shine your administration, sales, purchasing, accounting, and engineering areas as well

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Cleanliness steps
Step 1: Determine cleanliness targets.

Step 2: Determine cleanliness assignments.

Step 3: Determine cleanliness methods.

Step 4: Prepare cleanliness tools.

Step 5: Implement cleanliness.


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Methods for cleanliness maintenance


Cleanliness Maintenance

Discovery of abnormality or slight defect


Cleanliness Maintenance

Instant Maintenance

Requested Maintenance

The operator immediately restore or improves upon the abnormality or slight defect.

If unable to immediately restore or improve upon the abnormality or slight defect, the operator requests help from the maintenance department.
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Steps for 5S-SET IN ORDER


You evaluate and improve the efficiency of your current workflow, the steps and motions employees take to perform their work tasks

Create a map of your workspace that shows where all the equipment and tools are currently located

Use the map to identify wasted motion or congestion caused by excessive distances travelled, unnecessary movement, and improper placement of tools and materials

Draw a map of a more efficient workspace, showing the rearrangement of every item that needs to be moved

Make a plan for relocating items that need to be moved so you can make your new, efficient workspace a reality

Post the drawing of the new workplace layout in your area


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SET IN ORDER Work Sheet

Item to relocate Old location Proposed location Appd. By Responsibility Time

Status

Date:

Dept:

Prepared by:
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Stages in development of orderliness for jigs and tools


Stage 0: No sense of Orderliness. (The workplace is in complete disorder.) Stage 1: Easy-to-understand Orderliness.. (Jigs and tools are kept in groups..)

Stage 2: Easy-to-confirm Orderliness.. (Visual confirmation of where to return jigs and tools.)

Stage 3: Orderliness so simple that workers can maintain it with their eyes closed.. (We know it by heart.)

Stage 4: Just let go Orderliness. (We do dont even have to return it.)

Stage 5: Orderliness eliminates some jigs and tools (We no longer need them.)
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5S-Standardize
Make sure that team members from every work area follow the sort, shine, and set-in-order steps
Share information among teams so that there is no confusion or errors regarding Locations Delivery, Destinations, Quantities Schedules, Downtime, Procedures and standards

Have everyone write down their ideas for reducing clutter, eliminating unnecessary items, organizing, making cleaning easier, establishing standard procedures, and making it easier for employees to follow the rules.

Make your standards are known to everyone so that anything out of place or not in compliance with your procedure will be immediately noticed.

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4. Seiketsu (standardisation)
Organisation
Ways to prevent generating unneeded items Because they are not needed Why throw the items away ? Throw away unneeded items

Orderliness
Ways to prevent back sliding in orderliness condition Because they tend to revert to their previous level Why 3S conditions deteriorate ? Arrange things in an orderly fashion

Cleanliness

Ways to prevent contamination Because it becomes dirty Why sweep the floor ?

Advanced level standardization

Clean dirty place

Basic level of standardization

Unneeded items are accumulating everywhere

No one know exactly where to find things

The workplace is dirty and nobody cares

No standardization

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Integrate 3S duties Into regular Work activities

Three salient points of visual 5S are Anyone should be able To distinguish between normal and abnormal conditions At a glance

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Three ways to develop unbreakable standardised cleanup.


Unbreakable organisation Unbreakable orderliness Unbreakable cleanliness

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Prevent unwanted items from accumulating (preventive organisation)


Procure and produce only those items which are required, only when they are required and in exact quantities.

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How to prevent accumulation of unwanted items


Procure and produce only what is needed, only when it is needed, and only in the amount needed.

Step 1

Step 2 The 5Ss (what, where, and how many)

Step 3

Step 4 Onepiece flow

Step 5 Pull production (kanban)

Step 6

Step 7

Awareness revolution

Line integration

Production leveling

Standard operations

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How to prevent things from putting back


Orderliness also implies its opposite (that is, the disorderly placement of things).

Preventive Orderliness means keeping Orderliness from breaking down.


Orderliness must be applied to everything from inventory to tools and from documents to stationary supplies to eliminate the inefficiency that results from the lack of orderly control of such items. To achieve preventive Orderliness 1. Make it difficult to put things in the wrong place 2. Make it possible to put things in the wrong place

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Techniques to eliminate need


Suspension Incorporation means creating a smooth flow of goods or operations in which 1. Jigs, tools, and measuring instruments are smoothly integrated and 2. Such devices are used without having to be returned Use elimination suspending or incorporating jigs, tools, or measuring instruments effectively eliminates the need to return them after each use.
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Techniques for achieving unbreakable orderliness


Tool unification combining the functions of two or more tools into a single tool Ex: fastener that require a screwdriver, conform to the same kind of screwdriver, flat-tip or Phillips. Tools substitution using some other tool to serve the tools function Method substitution efficiency can be improved by replacing a method with another method

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5S-Sustain
The gains you make during the above four steps are sustained when:

All employees are trained and use visual management techniques

The workplace is well ordered and adheres to the new procedures all your employees have agreed upon

Reevaluate your workspace using the Sustain Evaluation Form

Encourage and recognize the achievement of all work areas that are able to sustain their visual management efforts.

This helps your company to maintain a cycle of continuous improvement


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Sustain Evaluation Form

Visual Management Sustain evaluation Sort Are all items in the work area necessary? Have unnecessary items been red-tagged? Have red-tagged items been removed? Shine Have all ares been cleaned? Has a cleaning schedule established? Set in order Is the location for every item in the work area defined? Is every item in its defined location? Standardize Have standards been established? Are standards posted? Have comapany-wide standards been adopted in the area? Sustain Is the evaluation being completed on a regular basis? Are all schedules, such as the cleaning schedule, being followed?

Y/N

Comments

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5S Introduction steps
Step 1

Establish 5S promotion organization Establish 5S promotion plan Establish 5S campaign materials In-house education 5S implementation Red-tag strategy (for Organization)

Step 2 Step 3

Step 4

Step 5

Standardized Cleanup

Intensive Improvements
Signboard strategy (for Orderliness)

Cleanliness

Discipline

Step 6

5S evaluation and follow-up


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