Visual Managements

Factory is visually managed, when there are systems in place that enable anyone to
immediately assess the current status of an operation or process at a glance.
Real-time information and feedback regarding the plant status are provided.
Visual management includes:
a visual workplace
• signs
• painted floor areas
• direction of flow indicators
• shadow boards
• identified equipment, materials and locations (labels, color-coded markings)
a visual information system
• process documentation
• procedures
visual production control
• visual process indicators
• production status boards
• kanban visual signals

autonomation
• machines stop when a problem occurs

visual performance measurement
• quality control charts
• production performance
• status of the factory

visual safety management
• safety warnings
• precaution information

The benefits of visual management:
• employee involvement and motivation
• open communication
• quality and productivity improvement
• faster decision process
• decreased inventory
•Is a system of management that helps create and sustain competitive advantage for organizations.
•Translates critical organizational requirements into visual stimuli that cannot be ignored.
• Uses these visual stimuli to highlight, report, clarify, and integrate mission, vision, values and culture
into an organization's operating systems and performance requirements.
• Creates an environment that enhances employee commitment to the success of the organization by ensuring that the work environment and culture directly support the mission and values of
that organization.
• Addresses performance issues at many level and keeps people focused on the real mission and
goals of the organization.
• Provides a mechanism for continuous improvement through system alignment, goal clarity,
engagement of people in the process, and improved communication and information sharing
throughout the organization.

• Supports integration and alignment of organizational systems.
•Helps people feel, see, hear, and touch mission, vision, core values, and results required to
gain competitive advantage and improve performance.
• Highlights critical information in ways that cannot be ignored.
• Simplifies and improves the means of delivery of information and results.
•Clarifies the core work of the organization.
• Cuts through information overload so employees can see their results.
• Makes the work more meaningful and fun!

• Visual Management in Lean Manufacturing Means Seeing the Problems
We think of plastering charts, graphs, pictures, color coding, labels and work instructions all over
our plant like wall paper. Just as in the case of work instructions, this is just a partial truth
In the lean approach, visual management is more than just charts and pictures.
• visual management is about seeing.- Seeing the waste, seeing the problems, seeing the things needing improvement in addition to seeing the improvements from the eyes of the customer. In business, we have an extremely difficult challenge in seeing. We do not like to see
problems and we overlook waste as just a cost of doing business. We get defensive when problems
are brought to the attention of management (The higher up the organization, the more defensive).
In the shuffle to deflect blame, we stumble through the improvement process hoping it will get better.
Unwritten policies are followed like "never shut down the production lines" or "we need the parts now
so write an UAI (Us As Is) disposition".To move forward on your TPM journey, you must first recognized this weakness in business.
Open your eyes in Gemba. You can not improve what you do not see.

Visual Control

What is Visual Control?

• Visual control are means, devices, or mechanisms that were designed to
manage or control our operations (process) so as to meet the following purposes:
• make the problems, abnormalities, or deviation from standards visible to everyone
and thus corrective action can be taken immediately,
• display the operating or progress status in a easy to see format.
• provide instruction.
• convey information.
• provide immediate feedback to people.

Potential Benefits of Visual Control :

• Implementing Visual Control in the plant would help the companies to exposing abnormalities, problems, deviations, waste, unevenness, and unreasonability to people,
thus corrective actions can be taken immediately to:
• correct the problems,
• reduce manufacturing costs,
• reduce possible waste,
• shorten production lead time and thus keep the delivery due date.
• reduce inventory.
• ensure a safe and comfortable working environment.
• increase company's profit.

Visual Controls & Visual Managements

VISUAL CONTROLS:
• Various tools of visual management such as color-coding, charts, andon boards,
schedule boards, labels and markings on the floor.
VISUAL MANAGEMENT:
• When the normal state and abnormal state can be clearly and
visually defined, visual management is possible. In visual management, simple
visual tools are used to identify the target state, and any deviance is met with
corrective action.
Visual Management instructions should be unambiguous and clear. As much as possible both "what" and "why" should be obvious so there is no room for questioning in the critical moment. Instructions as visual management tools should make the abnormal condition very clear.