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Lean Thinking in Action

Observe and document processes,

expose waste,
remove waste

This module highlights Visual Management (VM) examples applied in factory and administrative areas.
Visual Management

Simple signals that provide an immediate

understanding of a situation or condition. They are
efficient, self-regulating, and (group) team-managed.

06/23/20 360vu ©2001 2

 Visual Management

Production/ Administrative/ Transactional examples:

 Standardized Metrics / Area Communications Board
 Safety, Quality, Delivery, Cost, Training, Recognition
 Customer visits / Travel / Vacation calendars
 In/Out (Visual office boards)
 Lines on the floor to delineate storage areas, walkways, work areas, etc.
 Kanbans (special in-baskets, color folders) – ‘immediate attention’
 Process Maps
 Command Media (Policy, Procedures, Work-Instructions, forms)
 Leader Standard Work
 Clearly marked department locations, including customers
 Safety – Evacuation Maps / Emergency Numbers

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Visual Management Model

Prevent
Abnormalities
(Error-Proof)

ol
tr
5
Stop Abnormalities
on
lC
(Prevent defects from moving on)
sua

4
Warn about Abnormalities
Vi

(Build in alarms)
3 Build Standards into the Workplace
Visual Display
2 Share Standards at the Site

SAFETY 1 Share Information

5S Workplace Organization

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 Production Charts/ Defective Display - example

Corrective
Action
Status

What is the major defect? Monthly pareto’s

Who is working on it? Where do we need to focus?
Internally?
Supplier?
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Sign boarding – example

Phone list – clear labels, pictures

06/23/20 360vu ©2001 6
Visual Display / labels – Office example

Cabinet contents – clear labels

06/23/20 360vu ©2001 7
Visual Control / clear drawer storage –
Office example

Organized Office Supplies

06/23/20 – identified 360vu
and ©2001
labeled 8
Visual Display / color code –
Office example

Mail cart color coded

06/23/20 by department/ location
360vu ©2001 9
Visual Management – Quotation activities

Business Metrics

06/23/20 360vu ©2001 10

Monitor – Monthly RFQ Performance

Visual Management/ Visual Control

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 Production - example

“Customer” or
Product Sign
Cell Metrics Posted Lean Plan
Posted at the start of the cell • General Cell Info
Quality Products • Vision
Delivery Customers • RAIL
Safety Phone List • Time Line

Quality
Speed

Safety

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 Production - example

“U-Shape” Cell
• Starts with assembly, flows to test, around to quality/final out
• Daily customer requirements on workstation PC
• Bottlenecks easily observed
• Manager, Mfg.E, Planning in the office at the end of the cell
Arrows on the floor
show the flow of the cell
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 Production - example

Point of Use
Located behind the work
Work Station stations
Good Lighting Racks on wheels make them
Shelving to hold assembly details easy to move
Ergonomic shelving Different color bins signify
Details are loaded from the back common use parts across
different cells

Drawers are labeled

Foam cutouts for tooling
In the drawers
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Production - example

Grid System
Allows for quick equipment moves

Tooling Cabinet
Located next to test equipment
Each tool is labeled

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 Standard Work: Layout and Sequence
Work Station Layout Standard Work Sequence
Takt Time = 2 Minutes

“U” – shape is
best layout

Personal Protective Equipment Quality Checks & Key Points

None Required

06/23/20 360vu ©2001 16

Revision Date: 14-Sept-2006
Standard Work: Shipping – Packing
Work Station Layout Standard Work Sequence
Takt Time = 2 Minutes
Task # Operation Description Time (sec.)
1 Verify Shipper Part Number
2 Verify Serial number
3 Check SPI for ship pack requirements
4 Get Correct Box (Dimensions)
5 Orient Box (unfold)
6 Tape bottom of box and flip it
7 Get bubble wrap and orientate on top of box
8 Put part in bag
9 Seal Bag (if required)
10 Put bag with part in box
11 Fold paperwork and place in box
12 Tape Box Shut
13 Place labels on box
14 Put sticky Pouch on box
15 Put in outgoing square for Water Spider
16 Clean up workstation

Personal Protective Equipment Quality Checks & Key Points

None Required

06/23/20 360vu ©2001 17

Revision Date: 14-Sept-2006
Visual Management (signs/ labels) - example

06/23/20 360vu ©2001 18

Production - example
Assy. Flow Cell Standard Work Sequence
Work Sequence Layout Takt = 22 Minutes

3  Mechanic at Bench #3
 Receive modules from Mechanics 1 & 2
 Complete final assembly EWI Ops 150-200
 Move completed fuel control to fuel test area
 Mechanic at Bench #2

2  Receive parts from Material Handler (on shelf)

 Complete assembly EWI Ops 100-140, then 90
 Pass completed module to Mech. 3; Repeat
 Mechanic at Bench #1
 Receive parts from Material Handler (on shelf)
 Complete assembly EWI Ops 000-090
1  Pass completed module to Mech. 3; Repeat

 PPE Required
 Safety Glasses in all manufacturing areas

Outline: 3291390-4
Date: 21-Nov-05
06/23/20 360vu ©2001 19
 Benefits Of Incorporating Standardization

Standard Work (S)

 Build to standardized sequence
 Build to Takt – Customer Demand
Kaizen (K)  Visually enables performance improvement
 Everyone engaged
 Continuous improvements
 Most are quick / incremental
 Eliminate waste S
Improvement

S K
S K
S K
K K K
K
K
Time
Rapidly Achieve And Hold Improvement Gains
06/23/20 360vu ©2001 20
 freeleansite.com

Lean Thinking in Action

Observe and document processes,

expose waste,
remove waste

This module highlights Visual Management (VM) examples applied in factory and administrative areas.