![Page 1: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/1.jpg)
1
Zeeshan Syed
Visual Management
QUICKSET-UP
Visual Management
![Page 2: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/2.jpg)
2
Zeeshan Syed
Visual Management
Visual Management
Module 1
![Page 3: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/3.jpg)
3
Zeeshan Syed
Visual Management
Visual Management Charter
Visual Management is promout as a workplace where
all associates understand and manage their own work
in a safe, clean, organized environment that fosters
open communication, pride, and continuous
improvement
![Page 4: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/4.jpg)
4
Zeeshan Syed
Visual Management
Visual Management Goals
• Make everyone’s job easier
• Give all associates a high degree of ownership in their work, and pride in their workplace
• Increase communication by making information easier to understand
• Improve company overall success
![Page 5: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/5.jpg)
5
Zeeshan Syed
Visual Management
Workshop Objectives
• Understand the 4 Phases leading up to Visual Management
of the Workplace
• Apply the concepts and techniques for each phase through
team exercises on the floor
• Understand how to use Visual Management and the
benefits it offers
![Page 6: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/6.jpg)
6
Zeeshan Syed
Visual Management
Desired Outcome
• Create a sense of “Who we are” and “What we do”
• Employ company standards to make key processes universally understood
• Make work decisions based on what we see
• Communicate all ways
• Make customer satisfaction visible
![Page 7: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/7.jpg)
7
Zeeshan Syed
Visual Management
Brainstorming Exercise
Let’s think about things
as they are today. ..
Do we work in a visual
workplace ?
![Page 8: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/8.jpg)
8
Zeeshan Syed
Visual Management
What is our current situation ?
How would you describe your current workplace situation?
Consider:
• Personal Safety
• Physical environment
• The processes
• Information access
Safety
W P O Process
People Data Machines
![Page 9: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/9.jpg)
9
Zeeshan Syed
Visual Management
Visual Workplace Vision
Describe your vision of what the ideal workplace is like
![Page 10: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/10.jpg)
10
Zeeshan Syed
Visual Management
• Visual Management is a set of techniques for creating a workplace
embracing visual communication and control throughout the work
environment.
• The visual management philosophy is underpinned by the view that ‘what
gets measured & displayed gets done’
• It makes it easy to understand the processes which have been put into
place
![Page 11: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/11.jpg)
11
Zeeshan Syed
Visual Management
VISION• The work environment should be immaculate, safe and self-cleaning
• Standards are easy to recognise and abnormal conditions are quickly identified,
enabling speedy analysis & resolution.• Performance and progress are readily
apparent to employees.• Plans are in place to significantly reduce or
remove waste and defects in the process.
![Page 12: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/12.jpg)
12
Zeeshan Syed
Visual Management
DisplaysTo make staff aware of
related data and information
– charts, graphs etc
ControlsTo guide the action of staff members – sign
boards, dos and don’ts signs
Two Tools of Visual Management
![Page 13: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/13.jpg)
13
Zeeshan Syed
Visual Management
• Using visual mechanisms to communicate information
• Visual display builds on the fourth ‘S’ (standardise)
• Show how to do the job (standard, agreed-upon best practice).
• Show how things are used.• Show performance status.• Identify hazardous areas
![Page 14: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/14.jpg)
14
Zeeshan Syed
Visual Management
TYPES• Product and process information
• Area information, boundaries• Standard work instructions - Standard work
charts, etc• Performance information - tracking against
key metrics• Status of current issues and improvement
activities• Schedules of maintenance, calibration or
other support activities
![Page 15: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/15.jpg)
15
Zeeshan Syed
Visual Management
• Goes beyond simply tracking and reporting performance and any
• Highlights deviations that occur from the planned outcomes.
• Many forms of visual control exist in the Lean workplace
![Page 16: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/16.jpg)
16
Zeeshan Syed
Visual Management
Basic types
• Shadow boards
• Indicators on various items e.g. gauges
• Heijunka boards – showing the status of daily schedules
• Design pull systems (Kanban)
![Page 17: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/17.jpg)
17
Zeeshan Syed
Visual Management
![Page 18: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/18.jpg)
18
Zeeshan Syed
Visual Management
BENEFITS
• Leads to information sharing.• Facilitates worker autonomy.• Supports elimination of waste.• Fosters continuous improvement.• Exposes abnormalities.• Enables quick response & recovery.• Promotes prevention.• Maintains the gains.
![Page 19: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/19.jpg)
19
Zeeshan Syed
Visual Management
3 BASIC STEPS REQUIRED
• There are three basic steps:
1) Organise the workplace using 6S
2) Ensure that all required work standards, instruction and related information are clearly displayed in workplace
3) Control workplace processes by exposing and stopping errors and by preventing future occurrences
![Page 20: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/20.jpg)
20
Zeeshan Syed
Visual Management
The Visual Workplace ...
• is safe
• is clean and organized
• is easily understood
• is managed through involvement by all
• creates high quality products
• communicates progress
• generates pride
![Page 21: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/21.jpg)
21
Zeeshan Syed
Visual Management
The Visual Management Assessment Test
In the visual workplace, anyone will easily know the:
who, what, when, where, why, and how of an area
within 5 minutes
![Page 22: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/22.jpg)
22
Zeeshan Syed
Visual Management
The 4 Phases to Visual Management
Workplace Organization
Visual Display
Visual Measures
VisualManagement
![Page 23: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/23.jpg)
23
Zeeshan Syed
Visual Management
Workplace Standards
• Definition
Objects or practices considered to be the example or model. Standards should be established by general team consensus.
![Page 24: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/24.jpg)
24
Zeeshan Syed
Visual Management
Why use standards ?
Workplace standards offer
these benefits:
• Universally understood
• Assure quality and consistency
• Eliminate variation
• Make abnormalities apparent
ALTO
![Page 25: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/25.jpg)
25
Zeeshan Syed
Visual Management
How many of these standards are standard in your plant ?
STANDARDCHANGEOVER CLOCK
![Page 26: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/26.jpg)
26
Zeeshan Syed
Visual Management
How many of these standards are standard in your plant ?
RED BOX SCRAP
![Page 27: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/27.jpg)
27
Zeeshan Syed
Visual Management
How many of these standards are standard in your plant ?
T P M
BOARD
![Page 28: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/28.jpg)
28
Zeeshan Syed
Visual Management
How many of these standards are standard in your plant ?
DOWNTIME / PRODUCTION DISPLAY
![Page 29: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/29.jpg)
29
Zeeshan Syed
Visual Management
How many of these standards are standard in your plant ?
B O S CHART
![Page 30: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/30.jpg)
30
Zeeshan Syed
Visual Management
Visual Management
Module 2
![Page 31: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/31.jpg)
31
Zeeshan Syed
Visual Management
How do we create Visual Management?
One phase at a time...
The 1st Phase is Workplace Organization
![Page 32: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/32.jpg)
32
Zeeshan Syed
Visual Management
Workplace Organization
A Vital Link To Continuous Improvement
![Page 33: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/33.jpg)
33
Zeeshan Syed
Visual Management
S5S’S
• Sort
• Stabilize
• Shine
• Standardize
• SustainSSSS
![Page 34: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/34.jpg)
34
Zeeshan Syed
Visual Management
SortThe First S
![Page 35: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/35.jpg)
35
Zeeshan Syed
Visual Management
First S - Sort
• Keep what is needed
• Eliminate what is not
• Identify what is out of place
• X - Tag
![Page 36: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/36.jpg)
36
Zeeshan Syed
Visual Management
Dark Corners and Healing Walls
![Page 37: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/37.jpg)
37
Zeeshan Syed
Visual Management
SortHere Is A Good Example
How can it be improved?
![Page 38: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/38.jpg)
38
Zeeshan Syed
Visual Management
X-Tag
• Select a X-Tag leader
• Identify what is not needed
• Attach X-Tag
• Move to holding area
• Determine time to hold
• Move to facility holding area
• Tag all Safety problems
X-Tag
![Page 39: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/39.jpg)
39
Zeeshan Syed
Visual Management
• Never used
• Once or twice a year
• Once a month
• Once a week
• Once a day or more
• Give, sell, or throw away
• Store in a distant place
• Store in the facility
• Store in the area
• Keep at the workplace or carry
How often is it used? What to do with it.
X-Tag Rule of Thumb
![Page 40: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/40.jpg)
40
Zeeshan Syed
Visual Management
X-Tag
Name:
Date: Removal Date
Location:
Reason for X-Tag:
![Page 41: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/41.jpg)
41
Zeeshan Syed
Visual Management
StabilizeThe Second S
Operator
![Page 42: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/42.jpg)
42
Zeeshan Syed
Visual Management
2nd S - Stabilize
• A place for everything and everything in its place
• outlines
• labels
• shadow boxes
• Designated responsibilities
• color coded maps
• X-Tag leaders
• Make everything easy to find, use, and return
![Page 43: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/43.jpg)
43
Zeeshan Syed
Visual Management
Does this look well stabilized?
![Page 44: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/44.jpg)
44
Zeeshan Syed
Visual Management
Outlines or Footprints
A little out of place
![Page 45: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/45.jpg)
45
Zeeshan Syed
Visual Management
The Third S
![Page 46: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/46.jpg)
46
Zeeshan Syed
Visual Management
3rd S - Shine
• Cleaning is inspection
• Make cleaning everyday work
• Assign responsibilities
• color coded maps
• rotate cleaning responsibilities
• Utilize downtime & help others
![Page 47: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/47.jpg)
47
Zeeshan Syed
Visual Management
Is This Your Locker Room?
![Page 48: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/48.jpg)
48
Zeeshan Syed
Visual Management
Before and After
![Page 49: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/49.jpg)
49
Zeeshan Syed
Visual Management
A well shined facility
![Page 50: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/50.jpg)
50
Zeeshan Syed
Visual Management
A well shined facility
![Page 51: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/51.jpg)
51
Zeeshan Syed
Visual Management
StandardizeThe Fourth S
![Page 52: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/52.jpg)
52
Zeeshan Syed
Visual Management
4th S - Standardize
• X-Tag procedures
• Holding areas
• Cleaning procedures
• Location of items
• Operating procedures
![Page 53: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/53.jpg)
53
Zeeshan Syed
Visual Management
A Place For Everything
Even rags, gloves, and trash
![Page 54: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/54.jpg)
54
Zeeshan Syed
Visual Management
A Place For Everything
Every item has a place, is labeled, and color coded
![Page 55: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/55.jpg)
55
Zeeshan Syed
Visual Management
Communicating What Goes Where
Simple but effective
![Page 56: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/56.jpg)
56
Zeeshan Syed
Visual Management
SustainThe Fifth S
![Page 57: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/57.jpg)
57
Zeeshan Syed
Visual Management
5th S - Sustain
• Make it a habit
• It takes doing something 21 times before it becomes a habit
• Proper training and communication
• Inform all employees (especially new ones)
• Support and cooperation from everyone
![Page 58: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/58.jpg)
58
Zeeshan Syed
Visual Management
Visual Ranges Make It Easier to Sustain
![Page 59: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/59.jpg)
59
Zeeshan Syed
Visual Management
Visual Ranges Make It Easier to Sustain
![Page 60: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/60.jpg)
60
Zeeshan Syed
Visual Management
Sustain
Everyone needs to do their part to keep things where and how they belong
![Page 61: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/61.jpg)
61
Zeeshan Syed
Visual Management
5S’S
• Sort• X - Tag• Keep what is needed
• Stabilize• A place for
everything• Everything in its
place
• Shine• Cleaning is inspection
• Standardize• Rules for the first 3 S’s
• Sustain• Make it habit• Cooperation
![Page 62: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/62.jpg)
62
Zeeshan Syed
Visual Management
CATEGORY ITEM Yes No OBSERVATIONSHave unnecessary items been X-tagged?Are items neatly arranged?Are walkways/work areas clearly outlined?Are designated areas marked for incoming material?
SORT Are materials located in designated areas?(Organization) Are designated areas marked for outgoing material?
Is outgoing material located in designated area?Are information boards orderly?Is indicated information found?Is information current?Do excess materials have a specific location?Are excess materials in their location?Is there a place for everything?Is everything in its place?
STABALIZE Is it easy to see what belongs where?(Orderliness) Are things put away after use?
Are tools organized and located in specific place?Are only red containers being used for scrap?Is rejected material properly identified?Is rejected material stored in a designated area?Is process scrap located in separate containers?Is defective material located in separate containers?Are sort and stabilize complete?Are work areas clean?Are aisles clear?Are tools clean?Is any material found on the floor?Is equipment clean?
SHINE Do machines show evidence of old oil leaks?(Cleanliness) Is cell inventory correctly identified?
5S Checklist
![Page 63: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/63.jpg)
63
Zeeshan Syed
Visual Management
5S Checklist
• Audits performed for 5S’s
• Visual display of current standings and progress
• Emphasis on Sustaining
5S Audit
Points Needing Attention
7
![Page 64: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/64.jpg)
64
Zeeshan Syed
Visual Management
5S Supportive Strategies
• Color coding
• Point of use
• Safety
![Page 65: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/65.jpg)
65
Zeeshan Syed
Visual Management
Color coding things is a fast, easy way to separate different items and to visually determine if something is misplaced
![Page 66: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/66.jpg)
66
Zeeshan Syed
Visual Management
Scrap
- Manufacturing scrap
- Tubing
- Mixed scrap-banding, cold rolled, stainless
- Process scrap
![Page 67: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/67.jpg)
67
Zeeshan Syed
Visual Management
Examples
![Page 68: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/68.jpg)
68
Zeeshan Syed
Visual Management
Examples
![Page 69: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/69.jpg)
69
Zeeshan Syed
Visual Management
Color Coded Scrap Hoppers
![Page 70: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/70.jpg)
70
Zeeshan Syed
Visual Management
Part Color Coding
Different color for each part number Colors correspond to colors of:
work units tooling gages fixtures settings
![Page 71: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/71.jpg)
71
Zeeshan Syed
Visual Management
Color Coded Dies
![Page 72: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/72.jpg)
72
Zeeshan Syed
Visual Management
Point of Use
• Tools
• Parts disposal
• Operating procedures
• Lock-out instructions
• Materials/Finished goods
• Information
Looking For Tools
![Page 73: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/73.jpg)
73
Zeeshan Syed
Visual Management
Point of Use
![Page 74: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/74.jpg)
74
Zeeshan Syed
Visual Management
Point of Use
Not enough room to store at the point of use, so make them mobile
![Page 75: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/75.jpg)
75
Zeeshan Syed
Visual Management
Point of Use
Fixtures rotate so they take up less space and are kept at the point of use
![Page 76: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/76.jpg)
76
Zeeshan Syed
Visual Management
Point of use
Information
![Page 77: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/77.jpg)
77
Zeeshan Syed
Visual Management
Safety: The 6th - S
Is of great concern when considering workplace organization
and the 5S’s
![Page 78: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/78.jpg)
78
Zeeshan Syed
Visual Management
Safety
Color coded guards and labeling
![Page 79: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/79.jpg)
79
Zeeshan Syed
Visual Management
Sufficient Room to Exit the Work Unit
One small exit for up to 9 operators
Exit
![Page 80: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/80.jpg)
80
Zeeshan Syed
Visual Management
Safety
Well labeled, but what keeps people out of coils?
![Page 81: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/81.jpg)
81
Zeeshan Syed
Visual Management
Safety
Color coded and visual
-easily accessible?
![Page 82: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/82.jpg)
82
Zeeshan Syed
Visual Management
Safety
![Page 83: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/83.jpg)
83
Zeeshan Syed
Visual Management
WPO Exercise
• 5S and WPO checklist
• X - Tag
![Page 84: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/84.jpg)
84
Zeeshan Syed
Visual Management
X-Tag
Name:
Date: Removal Date
Location:
Reason for X-Tag:
![Page 85: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/85.jpg)
85
Zeeshan Syed
Visual Management
X-TAG REPORT OUTAREA STUDIED: TEAM:DATE: PAGE: of
Name Item Quantity Reason for X-Tag RemovalDate
Cost
![Page 86: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/86.jpg)
86
Zeeshan Syed
Visual Management
5S CHECKLIST
Instructions: Take a look around the work area and do a visual inspection. As you do theinspection place a check mark in either the “OK” column or the “NOT OK” column. Then place anumerical value in the “POINTS” column. Scores should be from 1 to 3, as follows:
1 = non-existent, the team has made no progress in this area.2 = progressing, work has been done on this but the team lacks the discipline.3 = implemented, being done on a regular basis.
Please make any necessary comments in the “OBSERVATIONS” column.
CATEGORY ITEM OK NOT OK POINTS OBSERVATIONSHave unnecessary items been X-tagged?Are items neatly arranged?Are walkways/work areas clearly outlined?Are designated areas marked for incomingmaterial?
SORT Are materials located in designated areas?(Organization) Are designated areas marked for outgoing
material?Is outgoing material located in designatedarea?Are information boards orderly?Is indicated information found?Is information current?Do excess materials have a specificlocation?Are excess materials in their location?
![Page 87: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/87.jpg)
87
Zeeshan Syed
Visual Management
5S Audit
Points Needing Attention
![Page 88: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/88.jpg)
88
Zeeshan Syed
Visual Management
Module 3
![Page 89: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/89.jpg)
89
Zeeshan Syed
Visual Management
Phase 2 of Visual Management is …
![Page 90: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/90.jpg)
90
Zeeshan Syed
Visual Management
How do we create Visual Management?
One phase at a time...
The 1st Phase is Workplace Organization
The 2nd Phase is Visual Display
![Page 91: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/91.jpg)
91
Zeeshan Syed
Visual Management
Are we ready for Visual Display ?
Before Visual Display... Implement
5 S
![Page 92: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/92.jpg)
92
Zeeshan Syed
Visual Management
Phase 2: Visual Display
Definition:
A method to visually communicate important information in the workplace
Information regarding:
• Safety
• Quality
• Operations
• Equipment
• Work Environment
• Progress / Achievements
![Page 93: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/93.jpg)
93
Zeeshan Syed
Visual Management
Benefits of Visual Display
• Makes work safer and easier
• Communicates information about performance
• Makes standards visible
• Makes problems recognizable
• Creates a shared knowledge base
![Page 94: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/94.jpg)
94
Zeeshan Syed
Visual Management
Visual Display tells others…
what is important to our company.
![Page 95: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/95.jpg)
95
Zeeshan Syed
Visual Management
Types of Visual Display
Begin implementing Visual Display with:
• Designated Locations
• Indicate danger; Set limits; Make work easier
• Information Boards
• Work Instructions
• Checklists
![Page 96: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/96.jpg)
96
Zeeshan Syed
Visual Management
Start with Designated Locations
Designated Locations:
• Indicate danger
• Set limits
• Tell us what, where, and how
many
Designated Locations are the first type of Visual
Display to be implemented
![Page 97: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/97.jpg)
97
Zeeshan Syed
Visual Management
Designated Location Example
This location is
exclusively for
fire safety
![Page 98: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/98.jpg)
98
Zeeshan Syed
Visual Management
Designated Location Example
Components Kanban: What, Where, and How many
![Page 99: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/99.jpg)
99
Zeeshan Syed
Visual Management
Floor Labeling Example
![Page 100: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/100.jpg)
100
Zeeshan Syed
Visual Management
Designated Location Example
![Page 101: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/101.jpg)
101
Zeeshan Syed
Visual Management
Would you pay for a dozen eggs ?
Eggs Grade A
![Page 102: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/102.jpg)
102
Zeeshan Syed
Visual Management
Designated Location Example
Egg Carton Display
![Page 103: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/103.jpg)
103
Zeeshan Syed
Visual Management
Designated Location Guidelines
• Determine appropriate location for all needed items
• Designate locations for type and correct number (quantity) of needed items
• Post visual indicators
• Create ways to recognize at-a-glance when items are out of place
![Page 104: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/104.jpg)
104
Zeeshan Syed
Visual Management
Mobile cart provides designated location and point of use flexibility
Could this idea
make work
easier for anyone
in your plant ?
![Page 105: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/105.jpg)
105
Zeeshan Syed
Visual Management
Make Visual Displayeasy, convenient, manageable
![Page 106: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/106.jpg)
106
Zeeshan Syed
Visual Management
Other types of Visual Display
Work Instructions
Information Board
T P M Checklist
![Page 107: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/107.jpg)
107
Zeeshan Syed
Visual Management
Visual Work Instructions
What do size and placement of work instructions tell us ?
![Page 108: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/108.jpg)
108
Zeeshan Syed
Visual Management
Product Boundary Sample Display
• Increases quality awareness
• Reduces variation
• Useful training aid
• Creates pride in products made
Need a new example of Boundary Sample!!!!
![Page 109: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/109.jpg)
109
Zeeshan Syed
Visual Management
Raw Material Boundary Samples
• Set quality standards
• Operators make quality decisions
• Create shared product knowledge
Use photos when actual samples are not practical
![Page 110: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/110.jpg)
110
Zeeshan Syed
Visual Management
Information Board Examples
![Page 111: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/111.jpg)
111
Zeeshan Syed
Visual Management
Information Boards
• What is the focus of this information board ?
![Page 112: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/112.jpg)
112
Zeeshan Syed
Visual Management
Saf
ety
Cle
anin
g -O
rgan
izin
g
Tea
m M
eetin
gs &
Act
iviti
es
Env
ironm
enta
l Man
agem
ent
Man
agem
ent
at a
Gla
nce
Pro
cess
C
apab
ility
& C
ontr
ol
Pro
blem
Sol
ving
& A
void
ance
Cou
pled
Man
ufac
turin
g
Pro
duct
ion
Sch
edul
ing
Wor
k S
tand
ards
Qua
lity
Sys
tem
Em
ploy
ee C
omm
itmen
t
Sup
plie
r D
evel
opm
ent
Kno
wle
dge
Util
izat
ion
Ski
ll V
ersa
tility
& C
ross
-Tra
inin
g
Del
iver
y P
erfo
rman
ce
Pre
vent
ive
Mai
nten
ance
Qua
lity
Ass
uran
ce A
ppro
ach
Man
agem
ent
of O
bjec
tives
Qui
ck C
hang
eove
r
5
4
3
2
1
Pe
rfo
rman
ce L
evel
W O R L D C L A S S
B E S T I N C L A S S
L E A R N I N G
L E A D I N G
Pe
rfo
rman
ce L
evel
T R A D I T I O N A L
5
4
3
2
1
20 Keys of Continuous Improvement Work Unit
1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 202
Goal
Current
![Page 113: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/113.jpg)
113
Zeeshan Syed
Visual Management
Sa
fety
/He
alth
Le
ad
ers
hip
Vis
ion
& E
xecu
tive
Sp
on
sors
hip
Ob
ject
ive
s/Im
pro
vem
en
t P
lan
nin
g
Co
mm
un
ica
tion
Le
arn
ing
& P
ers
on
al S
kills
De
velo
pm
en
t
Ma
na
gin
g C
ha
ng
e
Te
am
Bu
ildin
g /
Te
am
wo
rk
Pro
ble
m A
void
an
ce
Ide
a I
mp
lem
en
tatio
n
Ne
w P
rod
uct
/Pro
cess
In
tro
du
ctio
ns
Inte
rna
l Cu
sto
me
r F
ocu
s
Te
am
Re
cog
niti
on
Ext
ern
al C
ust
om
er
Fo
cus
Su
pp
lier
De
velo
pm
en
t
C I
To
ol U
tiliz
atio
n
Pe
op
le S
up
po
rtiv
e P
ract
ice
s
Va
luin
g C
on
tinu
ou
s Im
pro
vem
en
t
En
viro
nm
en
t
Be
st P
lace
To
Wo
rk
5
4
3
2
1
Per
form
ance
Lev
el
W O R L D - C L A S S
BEST IN CLASS
L E A R N I N G
L E A D I N G
Per
form
ance
Lev
el
T R A D I T I O N A L
5
4
3
2
1
20 Keys of Site Excellence
1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 202
Goal
Current
11-8
![Page 114: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/114.jpg)
114
Zeeshan Syed
Visual Management
Information Board Guidelines
• Work Unit determines what will be displayed
• Make information easy to read and understand
• Always post information in same location
• Keep the focus clear; don’t overload info
• Keep information current
![Page 115: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/115.jpg)
115
Zeeshan Syed
Visual Management
Other Types of Visual Display
• Status Boards
• Product Displays
• Storyboards / Pictures
• Electronic Marquees
Business Unit Display
![Page 116: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/116.jpg)
116
Zeeshan Syed
Visual Management
The best visual displays are easy to understand
Symbols
• are easily understood
• give immediate status
• engage viewer’s attention
![Page 117: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/117.jpg)
117
Zeeshan Syed
Visual Management
Symbols make status visible andeasy to understand
What other information might be useful here ?
![Page 118: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/118.jpg)
118
Zeeshan Syed
Visual Management
What do these symbols tell us?
P1 Device
CAPABILITYMachine NumberMachine TypeRestudy DatePerson Responsible
Characteristic
Po
ten
tial
Stu
dy
Lo
ng
Ter
mS
tud
y
Cp Cpk Study Date
Capable
![Page 119: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/119.jpg)
119
Zeeshan Syed
Visual Management
Pictures Display Before and After
Improvements are easily documented with pictures
![Page 120: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/120.jpg)
120
Zeeshan Syed
Visual Management
TPM Before and After ( Storyboards )
![Page 121: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/121.jpg)
121
Zeeshan Syed
Visual Management
To add impact
to visual displays,
relate items to
a cost.
![Page 122: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/122.jpg)
122
Zeeshan Syed
Visual Management
Product display for waste awareness
![Page 123: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/123.jpg)
123
Zeeshan Syed
Visual Management
Using Visual Display to show operating supplies cost
![Page 124: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/124.jpg)
124
Zeeshan Syed
Visual Management
Product Display Example
Display used as a problem-solving tool
Sample
assemblies
are added
to display
every 2 hours
![Page 125: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/125.jpg)
125
Zeeshan Syed
Visual Management
Team decision-making tools
How do balance boards and cross training charts become team decision making tools ?
![Page 126: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/126.jpg)
126
Zeeshan Syed
Visual Management
25%Able to processw/ direction
50%Able to processw/out direction
100%Able to train entire process
Employee Name
Skills Assessment
James
Jerry
Dawn
75%Able to processand problem solve
Cross Training Chart
![Page 127: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/127.jpg)
127
Zeeshan Syed
Visual Management
Everyone knows,“Safety is our Top Priority”
![Page 128: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/128.jpg)
128
Zeeshan Syed
Visual Management
Lost Time Accidents
• Goal is “Zero Accidents”
• Always keep displays up to date
• Changing the display daily focuses our attention on safety -daily
![Page 129: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/129.jpg)
129
Zeeshan Syed
Visual Management
Lighted displays capture attention
What audio warnings exist for safety concerns?
![Page 130: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/130.jpg)
130
Zeeshan Syed
Visual Management
These standard lighted displays provide …
• Consistency
• Easy visibility
• Status at a glance
• Problem recognition
• Team encouragement
![Page 131: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/131.jpg)
131
Zeeshan Syed
Visual Management
Marquee Information Display
What are other good uses for marquee displays ?
![Page 132: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/132.jpg)
132
Zeeshan Syed
Visual Management
Visual Displays asAs Voice to our Visitors
• Share success stories
• Recognize team
achievements
• Communicate pride in our
work
![Page 133: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/133.jpg)
133
Zeeshan Syed
Visual Management
Team Territory
This area is the team’s domain, but it is seen by all
![Page 134: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/134.jpg)
134
Zeeshan Syed
Visual Management
Team Territory is a place to ...
• hold shift startup meetings
• identify the team
• exhibit products made
• be managed by the team
• communicate team goals
• display team accomplishments
![Page 135: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/135.jpg)
135
Zeeshan Syed
Visual Management
• A daily working session at the start-up of the shift that’s: A daily working session at the start-up of the shift that’s:
• Short, every day, each shift and in each work unitShort, every day, each shift and in each work unit
• A consistent method to communicate essential information A consistent method to communicate essential information
• A way to accelerate the dissemination of essential information A way to accelerate the dissemination of essential information
• A daily discipline that helps improve team performance daily A daily discipline that helps improve team performance daily
• An opportunity to refer to and update the Primary Visual Display An opportunity to refer to and update the Primary Visual Display
• A essential tool to help create & maintain team involvementA essential tool to help create & maintain team involvement
Daily shift start-up meetings are the place to communicate and share news and information.
Shift Start-Up Meetings
![Page 136: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/136.jpg)
136
Zeeshan Syed
Visual Management
• The meeting is short and very focused The meeting is short and very focused
• 10 minutes maximum10 minutes maximum
• Centered on daily issues and activities Centered on daily issues and activities • Meeting held with entire team and facing the Primary Visual DisplayMeeting held with entire team and facing the Primary Visual Display
• Participants stand during the meetingParticipants stand during the meeting• Team members take turns being the facilitatorTeam members take turns being the facilitator
• Initially this is led by supervision Initially this is led by supervision
• Note: Could be up to a month until the team is confident with what to do and natural Note: Could be up to a month until the team is confident with what to do and natural leadership begins to emerge – still, it’s important to give everyone an opportunity to leadership begins to emerge – still, it’s important to give everyone an opportunity to facilitate the meeting and supervision often continues to participate to offer support, facilitate the meeting and supervision often continues to participate to offer support, help remove obstacle and roadblocks and stay in tune with issues. help remove obstacle and roadblocks and stay in tune with issues.
• Team records decisions, actions & next steps on Primary Visual DisplayTeam records decisions, actions & next steps on Primary Visual Display
• No formal/Computerized report writing desirable or necessaryNo formal/Computerized report writing desirable or necessary• Other discussions should happen outside this meetingOther discussions should happen outside this meeting
Shift Start-Up Meetings
![Page 137: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/137.jpg)
137
Zeeshan Syed
Visual Management
Common Territory
Shared Territory
Provide teams the territory they need to succeed
![Page 138: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/138.jpg)
138
Zeeshan Syed
Visual Management
P R O D U C T I O N P R E S SA R V I N E X H A U S T - F R A N K L I N P L A N T O c t o b e r 1 7 , 1 9 9 7
F L O W E R - C o s m o s B I R T H S T O N E - O p a l
H a p p y B i r t h d a y1 0 / 1 7 A u d r e y L u c a s
1 0 / 1 8 L u l a V a n d e v e n t e r
S i b e r t o G o n z a l e s
D a v i d K o o n s
J a m e s P a t t o n
1 0 / 1 9 J u d y H i c k s
1 0 / 2 1 L a r r y B u r t o n
C a t h e r i n e M c T a r s n e y
A n g i e F r e e m a n
D o u g l a s H u t c h e r s o n
D a v i d T h o m a s
T r a v i s B u r t o n
1 0 / 2 2 P h i l l i s B u r r i s
T i m o t h y S n e e d
L o r i S m i t h e r
T o n y a J o n e s
W a r r e n B e e l e r
R a n d y F i s h e r
1 0 / 2 3 D e b b i e W a r d
Q U O T E S O F T H EW E E K :
“ I f y o u f e e l d o g t i r e d ,m a y b e i t i s b e c a u s e y o u h a v eg r o w l e d a l l d a y ”
“ A l i t t l e k i n d n e s s m a y m o l d afi n e c h a r a c t e r . ”
U N I T E D W A YW I N N E R - T V
O n O c t o b e r 1 0 t h , t h e w o r k e r s i n v o l v e di n t h e U n i t e d W a y - P a c e s e t t e rC a m p a i g n a t t h e F r a n k l i n P l a n t , w e r ep r e s e n t f o r d i s c u s s i o n o f t h i s y e a r ' sU n i t e d W a y d r i v e . T h o s e p r e s e n td i s c u s s e d i d e a s f o r f u t u r e a c t i v i t i e s i nt h e U n i t e d W a y p r o g r a m a t t h i s P l a n t ,a n d w e a l l w i s h t o T h a n k t h o s e t h a ts i g n e d u p o r i n c r e a s e d t h e c o n t r i b u t i o nt o t h e U n i t e d W a y D r i v e .T h e h i g h l i g h t o f t h e l u n c h m e e t i n g w a st h e d r a w i n g f o r t h e C o l o r T V s e t t h a tw a s a w a r d e d t o a " C o n t r i b u t o r " , t o t h i sy e a r s p r o g r a m . T h e l u c k y w i n n e r w a s :K e i t h R . P a r k - f r o m F P O S e c o n d S h i f t( p i c t u r e d a b o v e , r i g h t , w i t h F a c i l i t y M a n a g e r , B o bE l l i o t t ) C o n g r a t u l a t i o n s K e i t h ! ! ! ! !
Plant newspapers
provide excellent
opportunities
for recognition of
employees !
Extra ! Extra ! Extra !
![Page 139: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/139.jpg)
139
Zeeshan Syed
Visual Management
Customer / Supplier Information
• What do we produce?
• What is it used for / on?
• Who do we contact if we have problems?
• Who supplies our materials?
• Where do our finished goods go?
![Page 140: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/140.jpg)
140
Zeeshan Syed
Visual Management
Customer / Supplier Display
What is being produced here?
Where is the product used?
![Page 141: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/141.jpg)
141
Zeeshan Syed
Visual Management
Exhaust assembly display with vehicle application
![Page 142: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/142.jpg)
142
Zeeshan Syed
Visual Management
How to implementVisual Display
• Identify subject to focus on
• Identify problems or success associated with the subject
• Identify the audience for visual display
• Choose the best location for the display
• Develop and test the display
• Improve, finalize, and implement the display
![Page 143: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/143.jpg)
143
Zeeshan Syed
Visual Management
Review: Does your visual display offer these
benefits?
• Communicate information about performance
• Make standards visible
• Makes problems recognizable
• Make work safer and easier
• Recognize an achievement
• Creates a shared knowledge base
![Page 144: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/144.jpg)
144
Zeeshan Syed
Visual Management
Remember...Your Visual Displays tell others...
what is important to ourcompany!
![Page 145: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/145.jpg)
145
Zeeshan Syed
Visual Management
Visual Management
Module 4
![Page 146: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/146.jpg)
146
Zeeshan Syed
Visual Management
Phase 3 of Visual Management is …
![Page 147: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/147.jpg)
147
Zeeshan Syed
Visual Management
How do we create Visual Management?
One phase at a time...
The 1st Phase is Workplace Organization
The 2nd Phase is Visual Display
The 3rd Phase is Visual Measures
![Page 148: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/148.jpg)
148
Zeeshan Syed
Visual Management
Visual Measures
In this module we will discuss:
• Using the data we collect
• Seeing is believing
• Measurement tools
• Effective data display
• BOS Charting
• How to develop meaningful measures
![Page 149: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/149.jpg)
149
Zeeshan Syed
Visual Management
Why do we use measurement data?
• To make more informed
decisions about our
operations
• To keep management
and shop floor
associates informed of
progress
If you are not going to use data, don’t collect it!
• To drive and fine-tune our
improvement activities
• To educate the plant
community
![Page 150: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/150.jpg)
150
Zeeshan Syed
Visual Management
Seeing is believing !
• Effective analysis requires effective reporting
• How we report and display data will affect how we think about it
I should haveimplemented this idea sooner!
![Page 151: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/151.jpg)
151
Zeeshan Syed
Visual Management
Lasting Impressions
To increase the impact of information:
• Make it sensory; use pictures, charts, sample products, and audio sounds that involve the audience
• Use examples and comparisons
• Make data speak; keep it visually appealing
• Don’t forget, “Keep it simple”
![Page 152: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/152.jpg)
152
Zeeshan Syed
Visual Management
To make data displays effective...
• Involve users in the measurement
• Provide the results to people who can act on them
• Present results in the most appropriate form for the audience
• Link results with improvement activities
• Report data immediately; date it; keep it current
![Page 153: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/153.jpg)
153
Zeeshan Syed
Visual Management
What do we measure ?
Uptime /Downtime
P P M ProcessCapability
SupplierQuality
Lost TimeAccidents
Floor Space
Manufacturing Scrap
Changeover Time
CrossTraining
![Page 154: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/154.jpg)
154
Zeeshan Syed
Visual Management
The Standards
Company recommends these standard measurement
tools be used to:
• Indicate status
• Collect data
• Solve problems
• Measure performance
![Page 155: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/155.jpg)
155
Zeeshan Syed
Visual Management
Company Standard Measurement Tools and Indicators
• Changeover Clock
• Production Counters
• Error Proof Symbols
• P.I. Indicator
• Lost Time Accidents
• 5 S Audit
• Downtime Clock
• Process Capability Logo
• Bottleneck Symbols
• Current Part Running
• Limbo Bars
• BOS Charts
![Page 156: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/156.jpg)
156
Zeeshan Syed
Visual Management
To increase information value . . .
• Insure data accuracy
• Put information in graphic form
• Place it where the work gets done
• Use it often to track improvements
• Keep it current
![Page 157: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/157.jpg)
157
Zeeshan Syed
Visual Management
Visual Production Counters
Visual production counters help us:
• Keep accurate counts• Make goals visible• Detect production
abnormalities • Satisfy customers
Goal / Actual / + or -
![Page 158: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/158.jpg)
158
Zeeshan Syed
Visual Management
Downtime / Product Count Example
![Page 159: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/159.jpg)
159
Zeeshan Syed
Visual Management
5S CHECKLIST
Instructions: Take a look around the work area and do a visual inspection. As you do the inspectionplace a check mark in either the “OK” column or the “NOT OK” column. Then place a numericalvalue in the “POINTS” column. Scores should be from 1 to 3, as follows:
1 = non-existent, the team has made no progress in this area.2 = progressing, work has been done on this but the team lacks the discipline.3 = implemented, being done on a regular basis.
Please make any necessary comments in the “OBSERVATIONS” column.
CATEGORY ITEM OK NOT OK POINTS OBSERVATIONSHave unnecessary items been X-tagged?Are items neatly arranged?Are walkways/work areas clearly outlined?Are designated areas marked for incomingmaterial?
SORT Are materials located in designated areas?(Organization) Are designated areas marked for outgoing
material?Is outgoing material located in designatedarea?Are information boards orderly?Is indicated information found?Is information current?Do excess materials have a specificlocation?Are excess materials in their location?
5 S Audit Tools
![Page 160: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/160.jpg)
160
Zeeshan Syed
Visual Management
Is there a visual measure of our Customer Satisfaction ?
• Collect customer satisfaction data
• Display it where everyone sees it
• Keep track of progress
• Highlight special achievements / awards
![Page 161: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/161.jpg)
161
Zeeshan Syed
Visual Management
Safety First ! Always.
• Make safety records visible
• Perform regular safety audits
• Display lost time injuries / accidents
• Keep track of where, when, why, and how accidents occur
![Page 162: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/162.jpg)
162
Zeeshan Syed
Visual Management
The Versatile BOS Chart
The BOS Chart can wear
many hats:
• Visual display
• Problem solving tool
• Progress indicator
• Assign responsibilities
![Page 163: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/163.jpg)
163
Zeeshan Syed
Visual Management
Follow these steps to use BOS for Visual Measures
The best reason to include BOS Charting with measure
displays is because BOS requires action !
Key Measurable
Data Analysis
Improvement Activities
Improvement Tracking
![Page 164: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/164.jpg)
164
Zeeshan Syed
Visual Management
25 50
10075
TREND LINE SUGGESTIONS
DATE:_______________
25 50
10075
25 50
10075
25 50
10075
25 50
10075
25 50
10075
25 50
10075
25 50
10075
Ref # Suggestions RespCompDate%Comp
Ref # Description
IMPROVEMENT TRACKINGANALYSIS (PARETO)
BOS Key MeasurableLINE:________________
![Page 165: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/165.jpg)
165
Zeeshan Syed
Visual Management
Step 1Involve users in the measurement
Team members collect data; track numbers:
• Total product produced
• per hour, per shift, per day, per week, etc.
• Average time to produce one unit
• PPM - number of defects
• Scrap - percentage of total produced
• Changeover time
• Downtime / Uptime
![Page 166: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/166.jpg)
166
Zeeshan Syed
Visual Management
Step 2Team determines what to BOS Chart
• Something needing
improvement
• Team has control
• Important to customer
• Important to our company
![Page 167: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/167.jpg)
167
Zeeshan Syed
Visual Management
Step 3Team members update BOS
• Use team meeting to study data
• Team plans improvement activities
• Everyone participates
• Computers not required
![Page 168: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/168.jpg)
168
Zeeshan Syed
Visual Management
Step 4Make BOS results visible at the Work Unit
![Page 169: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/169.jpg)
169
Zeeshan Syed
Visual Management
To develop Visual Measuresdecide . . .
• What needs to be measured ?
• Who is the user / audience ?
• How often do we take the data ?
• Who will do the tracking ?
• How will we display data so that it speaks ?
• Where do we best locate the display ?
![Page 170: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/170.jpg)
170
Zeeshan Syed
Visual Management
Reality Check for Measures
Answer these four questions about the measures you use:
• Are they simple and easy to use?
• Do they change over time?
• Do they provide rapid feedback?
• Do they foster continuous improvement?
![Page 171: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/171.jpg)
171
Zeeshan Syed
Visual Management
VISUAL DISPLAY & MEASURES AUDIT1. For each item listed fill in an observation to indicated whether or not the work group is currently working on this.2. If there are any changes desired please indicate those in the “Desired Changes” column.3. In the column labeled “Priority” indicate if the change can be implemented in:
1) 36 Hours2) 5 Days3) 2 Weeks
4. Fill in any additional items that are observed in the work area and fill in all categories.
ITEM OBSERVATION DESIRED CHANGES PRIORITYChangeover Clock Dedicated Line-clock is not
neededRedistribute the clock to a needy cell 1
P.I. Indicator
Production Counters
Changeover Graph
Bottleneck Operation
![Page 172: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/172.jpg)
172
Zeeshan Syed
Visual Management
Module 5
![Page 173: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/173.jpg)
173
Zeeshan Syed
Visual Management
How do we create Visual Management?
One phase at a time...
The 1st Phase is Workplace Organization
The 2nd Phase is Visual Display
The 3rd Phase is Visual Measures
The 4th Phase is Visual Management
![Page 174: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/174.jpg)
174
Zeeshan Syed
Visual Management
Visual Management
Using the information provided by visuals to make informed and proper decisions or judgements daily.
![Page 175: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/175.jpg)
175
Zeeshan Syed
Visual Management
Vision
The Visually Managed Factory is:
A workplace that is easily understood by all. Anyone could walk into a work unit and at a ‘glance’ understand the
status of that work unit, what is waste or abnormal, and where improvements are needed.
![Page 176: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/176.jpg)
176
Zeeshan Syed
Visual Management
Vision
If you walked into a work unit or facility on Sunday.
No one is around and nothing is running. Would you be able to understand the status of that work unit?
![Page 177: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/177.jpg)
177
Zeeshan Syed
Visual Management
Visual Management
• Status
• Distinguish between what is and is not normal
• Make waste and abnormalities obvious to everyone
• Constantly uncover needs for improvement
• Help make each persons job easier
• Involve everyone
![Page 178: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/178.jpg)
178
Zeeshan Syed
Visual Management
Status at a Glance
What information do we need to know?
• Is it?
• easily visible
• consistent throughout the facility or business unit
• current
• USEFUL
![Page 179: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/179.jpg)
179
Zeeshan Syed
Visual Management
Visual Management For:
• Workplace
• Safety
• Operations
• Equipment
• Quality
• Storage
![Page 180: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/180.jpg)
180
Zeeshan Syed
Visual Management
Status at a Glance
• Production counters
• Downtime/Uptime clocks
• Change-over clocks
• BOS charts
What do certain visuals communicate and how do we use them to manage?
![Page 181: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/181.jpg)
181
Zeeshan Syed
Visual Management
Status at a Glance
What do certain visuals communicate and how do we use them to manage?
•Safety
•PPM
•Scrap
![Page 182: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/182.jpg)
182
Zeeshan Syed
Visual Management
The following are some examples of these visuals or
measures.
•What do they communicate to us?
•How do they communicate it?
•What judgements or decisions do they help us to
make?
Visual Management
![Page 183: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/183.jpg)
183
Zeeshan Syed
Visual Management
Examples
![Page 184: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/184.jpg)
184
Zeeshan Syed
Visual Management
Examples
![Page 185: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/185.jpg)
185
Zeeshan Syed
Visual Management
Examples
![Page 186: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/186.jpg)
186
Zeeshan Syed
Visual Management
Examples
![Page 187: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/187.jpg)
187
Zeeshan Syed
Visual Management
Examples
![Page 188: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/188.jpg)
188
Zeeshan Syed
Visual Management
Examples
![Page 189: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/189.jpg)
189
Zeeshan Syed
Visual Management
Examples
![Page 190: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/190.jpg)
190
Zeeshan Syed
Visual Management
Needs for Improvement
Knowing very little about these facilities,
with the simple visuals we just looked at,
we were able to make some suggestions
for possible improvements.
![Page 191: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/191.jpg)
191
Zeeshan Syed
Visual Management
Needs for Improvement
• Utilize these visuals to make improvements and suggestions for improvements during:
• EI meetings
• Shift Start Up Meetings
• Downtime
• ALL the Time
![Page 192: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/192.jpg)
192
Zeeshan Syed
Visual Management
Standard Work Tools
Balance boards and equipment layouts are used to:
• Level work loads
• Make our jobs easier
• Processes better and more efficient
![Page 193: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/193.jpg)
193
Zeeshan Syed
Visual Management
Standard Work Tools
What does this tell us?
How would you use this to manage?
![Page 194: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/194.jpg)
194
Zeeshan Syed
Visual Management
25%Able to processw/ direction
50%Able to processw/o direction
75%Able to process& problem solve
100%Able to train otherson entire process
Pla
nt M
ater
ial I
nven
tory
Inte
r-P
lant
Tra
nsfe
rs (O
n-Li
ne)
Rad
io F
requ
ency
(RF)
Trak
ker S
cann
er (I
RL)
Haz
ardo
us M
at’l
Inve
ntor
y
Pla
nt B
atch
Rep
ortin
g
Employee Name
Skills Assessment
Kan
ban/
Sin
gle
Sca
n
Div
isio
n Ite
m
Inve
ntor
y B
ar C
ode
Inve
ntor
y R
ecei
ving
Joe
Bob
Betty
Cross Training Chart
![Page 195: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/195.jpg)
195
Zeeshan Syed
Visual Management
Designated Areas of Responsibility
• Color coded maps
• Who does what?
• How often do they do it?
![Page 196: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/196.jpg)
196
Zeeshan Syed
Visual Management
Red Box Scrap
• Separates non-conforming materials from product flow
• Gives a definite point for stopping the line and taking corrective action
• Promotes visual awareness of repetitive defects
![Page 197: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/197.jpg)
197
Zeeshan Syed
Visual Management
Red Box Scrap
• Are there less than 6 total or 3 identical parts in the box?
YES - continue production
NO - stop production and take corrective actions
![Page 198: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/198.jpg)
198
Zeeshan Syed
Visual Management
Red Box Scrap
![Page 199: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/199.jpg)
199
Zeeshan Syed
Visual Management
Control Ranges
![Page 200: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/200.jpg)
200
Zeeshan Syed
Visual Management
Error Proofing Program
P1 Device(Green)
An Error Proofing device that PREVENTS an error from occurring
![Page 201: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/201.jpg)
201
Zeeshan Syed
Visual Management
Error Proofing Program
P2 Device(Purple)
An Error Proofing device that DETECTS an error in time to allow rework and prevents further errors of the same type
![Page 202: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/202.jpg)
202
Zeeshan Syed
Visual Management
Error Proofing Program
P3 Device(Blue)
An Error Proofing device that detects a defect and ELIMINATES IT FROM THE FLOW of good products
![Page 203: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/203.jpg)
203
Zeeshan Syed
Visual Management
Process Capability
![Page 204: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/204.jpg)
204
Zeeshan Syed
Visual Management
CAPABILITYMachine NumberMachine TypeRestudy DatePerson Responsible
Characteristic
Po
ten
tial
Stu
dy
Lo
ng
Ter
m
Stu
dy
Cp Cpk Study Date
Capable
![Page 205: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/205.jpg)
205
Zeeshan Syed
Visual Management
CAPABILITYMachine NumberMachine TypeRestudy DatePerson Responsible
Characteristic
Po
ten
tial
Stu
dy
Lo
ng
Ter
m
Stu
dy
Cp Cpk Study Date
Not Capable
![Page 206: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/206.jpg)
206
Zeeshan Syed
Visual Management
Visual Management
Are WE Hitting the Target?
![Page 207: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/207.jpg)
207
Zeeshan Syed
Visual Management
Do Our Visuals:
• Give you the information needed to make proper decisions?
• Make abnormalities and problems obvious?
• Promote communication and employee involvement?
• Make everyone's jobs easier?
• Recognize achievements and improvements?
![Page 208: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/208.jpg)
208
Zeeshan Syed
Visual Management
The Visual Management Check List and Implementation
![Page 209: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/209.jpg)
209
Zeeshan Syed
Visual Management
THE VISUAL FACTORY CHECKLIST
ATEGORY ITEM YES NOChangeover tools are within reachTooling is well organizedMachines and equipment are clean and paintedUnnecessary items are clearedWorkplace organization and orderliness
5S Aisles are well marked and clearThere is a place for everything and everything in its placeHousekeeping responsibilities are assignedDisciplined approach to clean work areaAll bins are labeled and no parts are on the floorAll personal items are stored in lockersMethod to identify hold and reject partsSupplier defects are segregatedBusiness Unit/department display visibleCell displays conform to the unit/department standardsUsing standard changeover clockPart counter displayedDowntime clock in useRed box scrap method in useWork instructions displayed at the point of useMin/Max Limbo bars for inventoryCurrent part number and next part number displayedKanban system in useKanban system for MROKanban system for ToolingFirst piece displayedBoundary Sample board
VISUAL Customer/Supplier information displayedDISPLAY Bottleneck machines are identified
Bottleneck cycle time is on the balance boardChangeover signal to synchronize cellChangeover stock staging area for fast changeoverError proofing devices are on the PM checkATPM boards using tags and action status in each cellCumulative downtime clock displayed in each cellProper lighting and air handlingCell number, customer and product posted at each cellEmployee information board is in a standard formatKey measures are trended and up to dateTeam project display with before/after/future picturesDefects are displayed with arrows and action plansSafety rules are posted and followedColor coding and symbols are used for quick identification
![Page 210: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/210.jpg)
210
Zeeshan Syed
Visual Management
THE VISUAL FACTORYIMPLEMENTATION PLAN
Implementation Objectives:1. Begin immediately and involve all cell members.2. Capture before condition.3. Identify areas of greatest opportunity.
Activities Week 1: Responsible:
Activities Week 2: Responsible:
Activities Week 3: Responsible:
Activities Week 4: Responsible:
Key Support People:
![Page 211: "Visual management & 5S " in Lean T.P.S (Workshop slides)](https://reader036.vdocument.in/reader036/viewer/2022081502/5588f58cd8b42a53138b46dc/html5/thumbnails/211.jpg)
211
Zeeshan Syed
Visual Management
End of Visual Management