P3 VISUAL MANAGEMENT

INTRODUCTION
1. Provide real-time information on work
place status by a combination of simple,
effective visual information aids that allow
employees to understand their influence
on the organization overall performance
hence allowing the employees to improve
their performance.

P3 VISUAL MANAGEMENT

OBJECTIVE
1. Expose waste so that it can be eliminated and prevented from recurring
making the workplace more efficient.
2. Make abnormalities in the 4Ms (Man, Machine, Material, Method) process
inputs visible to everyone for prompt corrective action.
3. Enable trends in QCDMS & abnormalities to be visible for timely preventive
action to be taken.
4. Motivates everybody to improve by clarifying key performance targets.
5. Makes operation standards quicker and easier to understand by all
employees so they can follow them.
6. Builds participation through shared information.
7. Creates flow in the value stream and allows pull to the voice of the
customer.

P3 VISUAL MANAGEMENT

9 VISUAL MANAGEMENT AREAS

Quality

Delivery

Cost
S.H.E
MAN

VISUAL
MANAGEMENT
KPIs

MACHINE

MATERIAL

METHODS

MAKE ABNORMALITIES &

STATUS VISIBLE

P3 VISUAL MANAGEMENT

PRINCIPLES OF VISUAL MANAGEMENT

SAFETY
SAFETY

VISUAL
FACTORY

PRODUCTIVITY
PRODUCTIVITY

QUALITY
QUALITY

Hazards Visual Recognition

Safe Areas Visual Display
5S Eliminates Workplace Clutter
Awareness of Safety Measures

Associates Works Progress

Production Rate
Progress Towards Goals
Production Status
Efficient Operators

Operator Prompts for Error Proofing

Clearly Marked Tools Reduce Errors
Visible Calls to Support Personnel for Parts
Shortage / Problems
Reduce Rework
Immediate Indication of Out of Tolerance
Variables

P3 VISUAL MANAGEMENT

VISUAL MANAGEMENT INITIATIVES

1. Visual Control Boards.
2. Andon
3. Footprints
4. Signage
5. Obeya
4. Hansei

P3 VISUAL MANAGEMENT

VISUAL BOARD
What is Visual Control Board
1. A color-coded , physical visual control system used for monitoring of shop-floor activities
and KPIs.

Use of Visual Control Board

1.
2.
3.
4.

Visual boards are used as activators and data communication centre.

The visual board area is used for shop-floor meetings.
A centre of periodical progress reviews and updates.
Used to drive the business processes from the boardroom to the shop floor.

Benefits of Visual Control Board

1. It quickly gives visibility to the progress of each tasks for further action.
2. Identifies the resources and activities being undertaken.

P2 VISUAL MANAGEMENT

VISUAL BOARD
Red zone indicates
the supplier is on the
verge of not satisfying
their customer. Very
low level of goods
maintained.

Yellow zone indicates

customer
requirements
are
being met. Low level
of finished goods
maintained.
Green zone indicates
the customers needs
are being fulfilled.
Supplier is building
more
than
the
customer is requiring
and it may be time to
stop production until
demand is more in
line with supply.

Other pertinent information

(e.g.. Quality performance)
would be contained in the
information section.

The cards hanging on

the hooks in the
colored zones reflect
the
part
number
identified
in
the
section,
a
given
quantity of material in
one container. When a
card is on the hook it
indicates an empty
container.

This
This is
is an
an example
example of
of aa pull
pull board
board that
that could
could be
be used
used with
with internal
internal operations,
operations, as
as shown,
shown, or
or even
even
with
with external
external customers.
customers.

P3 VISUAL MANAGEMENT

ANDON
What is Andon
1. Andon (Japanese for lantern) is a tool for visual
management and refers to a system of signals
used to indicate the operational status (at a
glance) of a machine or work center.
2. It can be used manually or automatically.
3. It also one of the principle elements of the Jidoka
quality-control method.

P3 VISUAL MANAGEMENT

ANDON
Use of Andon
1. Alerts management and other workers to quality or
process problem.
2. Gives the worker the ability to stop production when a
defect is found, and immediately call for assistance.
3. Indicates where the alert was generated, and may also
provide a description of the trouble whether shortage of
material or maintenance call or supervisor call.
.

P3 VISUAL MANAGEMENT

ANDON
Defect created or found

Common reasons
for manual
activation of the
Andon

Part shortage

Equipment/Tool malfunction

A safety problem exists

P3 VISUAL MANAGEMENT

ANDON
Benefits of Andon
1. Reduces operation & maintenance costs by identifying problems before they become
major issues.
2. Increases equipment availability by making downtime issues more visible, thus
prompting immediate rectification to the issues.
3. Supports Jidoka implementation by making the problem status visual.

Mechanism of Andon
Abnormality

Andon Indicator

Response from
support team

P3 VISUAL MANAGEMENT

Types of Andon

ANDON

Visual Andon
Graphics

Text

Coded signal lights

Green - no problems

Ideal for STOP /

WAIT / GO signaling
in busy factories
Boost health and
safety.

Display production data in

real time.
Calculate shift efficiencies
and production targets.

Yellow - situation requires

attention, production flow at risk
Red - PRODUCTION STOPPAGE:
IMMEDIATE ASSISTANCE
REQUIRED

Audio Andon
Coded
Tones

Coded
Tunes

Buzzers /
Alarms

Prerecorded
Messages

P3 VISUAL MANAGEMENT

FOOTPRINT
What is Footprint
1. Markings on the floor or work area outlining specifically where items should be placed.

Benefit
1. To ease employees during storage or retrieval.
2. It avoids employees wasting time looking for things or pondering their next move.
3. The workplace becomes clean and better organized.
4. Operation on the shop floor and office become easier and safer
.
5. Visible location of parts or equipment for easy traceability and save time of searching

P3 VISUAL MANAGEMENT

FOOTPRINT
CREATING FOOTPRINT
1. A footprint is an outline of the items required at work areas indicating where the items
should be placed.
2. Rules about footprints or floor borders
a) Mark from the floor up to workbenches etc
b) Start with plastic tape to test out, then move to paint
c) Use colours to code footprints as shown in the following example, as a guideline :
Light Blue - Raw parts/material
Black - Finished good/parts
Red - Non-conforming/KIV parts/material
White - Other than parts/material
Yellow Border of work area

P3 VISUAL MANAGEMENT

FOOTPRINT
Yellow for work area border

Black for finished part

Light blue for raw material

LINE
SOZAI

5S CORNER

KANSEI

TOOL CABINET

NG

QC CORNER

Red for non-conforming part

White for equipment

VISUAL BOARD

P3 VISUAL MANAGEMENT

SIGNAGE
Signage is any kind of graphics created to display information.
Two types of signage
1. Displays
A visual display relates information and data to employees in the area. For example, charts showing
the monthly revenues of the company or a graphic depicting a certain type of quality issue that group
members should be aware of.

2. Controls
A visual control is intended to actually control or guide the action of the group members. Examples of
controls are: stop signs at intersections, handicap parking signs, or no smoking signs.

P3 VISUAL MANAGEMENT

SIGNAGE
Signage must be used appropriately for
providing pertinent information on:
hazardous and risky areas & installation
materials
safety measures
emergency exits, etc.

Signage shall be:

in accordance with international
standards, code of practice
maintained
up-to-date
be well known to, and easily understood
by employees, visitors and the general
public as appropriate
visible from at least 1.5m and easily seen
by forklift driver

AMS 9 PRINCIPLES

WASTE
WASTEELIMINATION
ELIMINATION

FLEXIBILITY
FLEXIBILITY

PRODUCTION
PRODUCTIONLEVELLING
LEVELLING

STANDARDISATION
STANDARDISATION

VISUALMANAGEMENT
MANAGEMENT
3 VISUAL
TOTALEMPLOYEE
EMPLOYEEINVOLVEMENT
INVOLVEMENT&&DEVELOPMENT
DEVELOPMENT
2 TOTAL

LONGTERM
TERMBUSINESS
BUSINESSTHINKING
THINKING
LONG

SH
SH

ST
QUALITY
QUALITYRIGHT
RIGHT11STTIME
TIMEEVERY
EVERY
TIME
TIME

PULL
PULLSYSTEM
SYSTEM

BESTQUALITY
QUALITY
LOWESTCOST
COST
BEST
LOWEST
BESTENVIRONMENT
ENVIRONMENT&&SAFETY
SAFETY
--BEST