1、The Lean EnterpriseVisual ManagementLean FoundationsContinuous Improvement TrainingLearning Objectives The purpose of the this module is:To introduce Visual Display/ Visual Control philosophies, actions and measurements. Explore and examine the benefits of adopting these Visual Management discipline

2、s.Understand and apply simple Visual Display and Visual Control techniques within a process step or work area.Simple Visual Display Board - exampleSafety logsHeadcount and Open PositionsVisitor ScheduleStreet signsAddressesScores during a gameOrganized grocery aislesAir traffic controlsDrive-through

3、 fast food restaurantsImagine a World Without Steps of the Levels (Pyramid Detail)5S Workplace OrganizationStop Abnormalities(Prevent defects from moving on)PreventAbnormalities(Error-Proof)6Warn about Abnormalities(Build in alarms)Build Standards into the WorkplaceShare Standards at the SiteShare I

4、nformation54321Visual DisplayVisual Control SAFETYVisual Management drives Self-controlling, Self-correcting Work AreasGuidelines for Visual Management:Charts & signs must be visible at a distance.They should be directed toward a group, not individuals.Visuals should communicate a standard and perfo

5、rmance to that standard.Involve all employees in the visual management process.Do not use visual management as a means to control or punish:Drive to solve problems in a blameless environment.Facility Map drives blameless environmentFacility Map w/ locations of all safety incidentsShare Standards:Red

6、 = Lost TimeBlack = First AidYellow = MedicalVisual Management - ExplanationsSigns/ Labels: Show Where Tools, Inventory, etc. Must GoWhite Demarcations: Tape or Paint Marks Off Pathways, Inventory Locations, etc.Red Lines/ Floor Marks: Show Where Inventory Should Be Stocked to (No Higher) - Sometime

7、s Written on Storage AreaAdd-ons: When Abnormalities Occur, Mounted Andons (Alarm Lamps) Will Alert Supervisors to the Problem ImmediatelyVisual Management - ExplanationsProduction Boards: Show Required & Actual Outputs for an AreaStandardized Work Chart: Easy-to-Read Graphical Representation of Pro

8、cess Layouts, Work Procedures, etcVisual Management - exampleDefective Item Displays: Shows Number of Defective Items & Types of Defects (i.e., Check sheets, Pareto Charts, etc.)Account ProcessingDefinition:A list of check-off items that permits data to be collected quickly and easily in a simple st

9、andardized format which lends itself to quantitative analysis.Purpose:Facilitates data collection by providing a standardized format for recording information.Example: Production Charts/ Defective Items displayMonthly paretosWhere do we need to focus?Internally?Supplier?What is the major defect?Who

10、is working on it?CorrectiveActionStatusVisual ManagementMore types of Visuals:Red Tag Strategy (5S Program)SignboardingLine DemarcationsFloors & AislesStack Height LimitsKanban (Office and Factory environment)Standard Worksheets (work instructions)Defective Item DisplaysRed TagItem number_Descriptio

11、n_Date Tagged_Tagged by_Circle one:Stored DisposedReason _Visual ManagementMore types of Visuals: Defective Item DisplaysVisual ManagementMore types of Visuals:Fluid level MarkingsDirection of rotation for motorsLube-point identificationStorage locations Tools, cleaning supplies, forklifts, material

12、 storage, etcHeat sensor stickersCharts showing normal operating rangesError prevention boards Show best practices on common errorsPurpose:Identify critical items, parts and areas within factories with common colors to allow any employee or visitor to easily understand Safety or production requireme

13、nts in each of our different businesses.Share Standards Color Coding (Level 2) - exampleShare Standards Color Coding (Level 2) - exampleExample: Defect warnings (Level 1) = = = = = = = = = = = = xxxxxxxxxxxxxxxxxxxxxxXxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx Example: Yellow hazard line (Level 2) Example: Labe

14、lled Stock (Level 1) Example: Scrap cage (red, locked) - (Level 5) Example: Accountability Meeting (Level 1) Example: Factory Flow Schematic (Level 3) = = = = = = = = = = = = = = = = Example: OTD metrics - (Level ?) Example: Safety Metrics (Level ?) = = = = = = = = = = = = = = = = = Area Communicati

15、on/ Accountability Scoreboard PossibilitiesKey CustomersProcess/ Function identificationSIPOC/ Process MapValue Stream Map (Present, Future States)A run/ control chart with GoalsPrioritization of ProblemsAction Plans and ProgressKey MetricsOthers?ExerciseItem to be controlled:Level 1- Share informat

16、ionLevel 2- Share standards at the siteLevel 3- Build standards into the workplaceLevel 4- Warn about abnormalitiesLevel 5- Stop abnormalitiesLevel 6- Prevent abnormalitiesIdentify Examples for your Project / areaHow will you achieve the next level ? Steps of the Levels (Pyramid Detail)5S Workplace OrganizationStop Abnormalities(Prevent defects from moving on)PreventAbnormalities