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Shop Floor - Visual Management

Zenaca Consulting Revision 0

Amarpreet Singh Nov 8, 2023
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Agenda
• Definition

• Functions of Visual Management

• Benefits

• Lean Tools for Visual Management

• Design Guidelines

• Implementation Guidelines

• Q&A

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Definition – Visual Management

Visual management is the display of information in the workplace to inform
teams, enforce work standards, and highlight or prevent problems.

• Visual management serves as a means of communication, providing a quick

overview of manufacturing operations.

• Visual management is a critical component of lean manufacturing and is used to

improve productivity, safety, and efficiency on the shop floor.

• The most obvious function of visual management is to share information. This is

done through dashboards, markings in the work environment, lights etc…
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Visual Management - Examples

ZENACA

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Function of Visual Management

1. Information Sharing

• The primary purpose of visual management is to communicate information

effectively. This is achieved using dashboards, markings on the shop floor, lights,
and similar visual elements.

Production Board – Manual Production Board – Digital Floor Markings

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Function of Visual Management

2. Standard Work

ü Once work standards have been established, visual

management comes into play to present these
standards in a relevant context, eliminating any Standard Work

ambiguity about what the standards entail.

ü By documenting the steps of a process and

incorporating visual cues in the physical environment
to direct the work, the work standards become readily
apparent to anyone approaching the workstation.
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Function of Visual Management

3. Highlight Abnormalities

o Utilizing visual management enables swift indication

of issues when they arise. Automated systems
prove beneficial for both supervisors and workers,
allowing them to concentrate on other
responsibilities until a problem is flagged.

Once an issue is identified, a prompt signal is

triggered, enabling a rapid resolution before returning
to their initial tasks. Andon Lights
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Function of Visual Management

4. Solve Problems

o Visual management is an effective tool for problem-

solving in various scenarios. For instance, when there is
recurrent confusion in a facility regarding a specific
location or process, implementing appropriate visual
management can address and resolve this issue.

In cases where operators frequently misuse a machine,

visual management can serve as a preventive measure by
Visual Management on Machine
clearly illustrating the proper usage of the machine, thus
averting potential problems.

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Visual Management - Benefits

Transparent processes

Implementing visual management facilitates a clear understanding of process dynamics for

all stakeholders. A well-crafted process design enhances the operator and supervisor
experience by making the workflow easily understandable and manageable.

Accountability and consistency

Visual management enhances accountability among workers by providing transparent

processes. When the details of a process are readily visible, subpar work has fewer
opportunities to go unnoticed. This fosters clear expectations and promotes improved
consistency in performance.
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Visual Management - Benefits

Work Simplification

Visual management streamlines work processes by eliminating ambiguity, enabling

operators and supervisors to concentrate on their assigned value-added tasks. It also reduce
obstacles by preventing interference between operators engaged in distinct tasks. In
essence, it assists workers and supervisors in maintaining their focus, ensuring a smooth
flow of work.

Accountability and consistency

Visual management facilitates real-time training by making the work intuitive. With clear
visual cues and guidance, most tasks become straightforward enough for an operator with
minimal experience to learn within short time.
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Visual Management – Lean Tools

• Kanban Boards: Utilizing columns and visual cues, • Kamishibai Boards: Employing cards to signify
Kanban boards visually depict work processes, scheduled tasks or audits, Kamishibai boards are
tasks, and their status. visual management tools that ensure regular checks,
audits, and adherence to standard work procedures.
They facilitate the monitoring and management of
workflow, enabling teams to visualize progress, pinpoint Tasks progress is indicated by moving cards from one
bottlenecks, and maintain a consistent workflow. column to another, ensuring timely completion

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Visual Management – Lean Tools

• Huddle Boards: Specifically designed for • 5 S Boards: This board is designed to
daily team huddles or stand-up meetings,
display the status of daily 5S audits on the
huddle boards display pertinent information
shop floor. This helps in understanding the
such as team goals, metrics, safety
5S status of the shop floor in real time.
updates, and initiatives for problem-solving.

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Visual Management – Lean Tools

• Value Stream Mapping : Visually illustrating • Visual Performance Dashboards: Performance
the flow of materials, information, and dashboards, such as Balanced Scorecards
processes within a value stream, VSM helps (BSC), visually present key performance
identify waste, bottlenecks, and metrics, goals, and targets.

improvement opportunities.

They offer real-time visibility into performance and encourage

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data-driven decision-making at various organizational levels.
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Design Guidelines
• Ensure Clarity and Conciseness: Guarantee that the information presented on the visual
management board is clear, concise, and easily comprehensible immediately. Employ
visuals, symbols, and colours to swiftly and effectively convey messages.

• Utilize Visual Hierarchy: Organize the information on the board in a logical and visually
appealing fashion. Use visual cues such as size, colour, and placement to signify the
importance or priority of different elements.

• Integrate Real-Time Data: Elevate the board's effectiveness by showcasing up-to-date

information, turning it into a potent tool for monitoring and decision-making. This may
include live production metrics, performance indicators, or ongoing progress updates.

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Design Guidelines
• Create Interactivity and Engagement: Foster a collaborative environment by
encouraging team members to contribute ideas, suggestions, or feedback.

• Consistency: Maintain consistency when employing multiple instances of the

same visual management tool.

• Visibility: Ensure key information is visible from 40 feet.

• Right Location of the Display: Present information in a location that is pertinent to

the user, ensuring user-specific relevance.

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Design Guidelines - Floor Markings

• These guidelines are
general in nature, and
certain organizations
establish their own
definitions for floor
markings.

Image credit - https://engg.directory/know-the-meaning-of-various-colour-coding-used-in-floor-marking

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Design Guidelines
• Like any other practice,
visual management can
be executed poorly. It's
notably common to go
overboard with excessive
markings.

• This is excessive. There

is no benefit to visual
management for
individual pens and
scissors, especially on a
personal desk.
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Visual Management - Implementation

Step 1: Identify key areas for visual management

• Production Floor: Visual management has the potential to enhance production processes,
reduce waste, and maintain seamless operations on the shop floor.

• Office Area: The implementation of visual management in office areas can streamline
workflow, foster information sharing, and elevate overall productivity.

• Project Management Boards: Visual tools prove invaluable in monitoring project progress,
pinpointing crucial milestones, and improving overall project coordination.

• Inventory Control: Utilizing visual management techniques can optimize inventory

management, guaranteeing precise stock levels and promoting efficient material flow.
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Visual Management - Implementation

Step 2: Selection of Right Tools

• Floor Markings and Colour Coding: Employ floor markings and colour coding to direct
movement, define work zones, and visually convey information or instructions.

• Visual Charts and Graphs: Utilize charts and graphs such as Pareto charts, Gantt charts, and
process flow diagrams to illustrate data, performance metrics, and trends.

• Task Boards and Kanban Cards: Integrate task boards or Kanban systems to visualize workflows,
monitor tasks, and manage Work In Progress (WIP). Kanban cards represent individual work
items or tasks.

• Andon Lights and Signals: Implement Andon systems with lights or signals to offer real-time
status updates, notify team members of issues, and facilitate a prompt response.
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Visual Management - Implementation

Step 3: Training and Team Involvement

• Training Employees: Conduct training sessions to familiarize employees with visual

management concepts, tools, and techniques.

• Encouraging Participation: Cultivate a culture of engagement by motivating team

members to share ideas, suggestions, and feedback related to visual management.

• Conducting Regular Meetings: Organize regular meetings to evaluate visual

management practices, address challenges, and share success stories, fostering a
culture of continuous improvement.

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Visual Management - Implementation

Step 4: Developing a Continuous Improvement Culture

• Identifying Bottlenecks and Inefficiencies: Consistently evaluate processes, pinpoint

bottlenecks, and employ visual management tools to rectify inefficiencies and promote
improvement.

• Utilizing PDCA (Plan-Do-Check-Act) Cycles: Integrate PDCA cycles to methodically

plan, execute, evaluate, and adjust visual management practices, fostering continuous
optimization.

• Celebrating Success and Acknowledging Efforts: Acknowledge and

celebrate the accomplishments and dedication of individuals and teams
who embrace visual management, contributing to positive outcomes.
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From chaos to clarity, visual management on the shop floor is the guiding map
to excellence and the pulse of operational excellence. – Amarpreet Singh

Thank You
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Do you have more questions on topic ?

Please reach me at
Email : [email protected]
Contact : +91 96866 83783
www.singhamarpreet.com

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