VISUAL CONTROLS - Mieruka

Presented By:
Jude Abreo (81) Ketan Mokal (82) Mridu Sharma (83)

LOGO
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Contents
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Introduction

Visual Control An Understanding

Advantages And Limitations Conclusion

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Introduction Basic Philosophy

1. Visual elements in a workplace have a tremendous impact on education, morale, and productivity. 2. A visually dynamic workplace energizes employees, builds pride and ownership, and conveys the strength and currency of the organization. 3. Design and graphics, art and color, sculpture and dimension all have profound effects. 4. Far from simply prettying up the office, they create an environment of visual stimuli that convey goals and expectations, that foster a collaborative attitude, and most important, that cannot be ignored!

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Introduction What is Visual control ? One picture is worth a thousand words

Visual control are means, devices, or mechanisms that were designed to manage or control our operations (processes) so as to meet the following purposes: 1. Make the problems, abnormalities, or deviation from standards visible to everyone and thus corrective action can be taken immediately (Identification). 2. Display the operating or progress status in a easy to see format (Informative). 3. Provide instruction (Instructional). 4. Helps formulate and proliferate plans (Planning). Thus all visual control devices can be classified as one of 3I1P. (Three Is and 1 p)

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Identification: Helps you know what something is. Forms Seen: Labels and stickers.

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Informative: Gives important information in an area to update status or situation. Forms Seen: Information walls, charts, informative sheets and diagrams.

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Instructional: Tells you how a task is to be performed. Forms Seen: Work instructions, floor markings and signs.
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Planning: Helps formulate the plan and let others know what the plan is. Forms Seen: Gantt charts and white board walls.

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Prerequisites
1. 2. 3.

Management must believe in openness and transparency. Employees have the ability to observe critically and share their feelings. Regular follow up at all levels about problems, facts and figures being shared

Implementation costs
Expenses required are relatively low (expenses for Andons, visual digital displays, etc.)

Implementation time
1. 2.

Visual controls are extremely easy to implement after 5S program initiation. The 4th S (Standardization) and Visual Control go hand in hand.

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Applicability / Adaptability
Visual Control is applicable to services, software and even in offices.

Training Needs
Low training requirements; information is simplified and can be understood by any one be it top management or line operators.

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Visual Control An Understanding Examples of visual controls: Visual Control Board

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Visual Control An Understanding Examples of visual controls: Shadow Board

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Visual Control An Understanding Examples of visual controls: Inventory Control

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Visual Control An Understanding Examples of visual controls: Level Scales

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Visual Control An Understanding Examples of visual controls: Visual Workstation

Work Instructions

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TPM Checklist Information Board

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Visual Control An Understanding Examples of visual controls: Color Codes

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Visual Control An Understanding Examples of visual controls: Andon Displays

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Visual Control An Understanding Examples of visual controls: What is Andon ?

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Jidoka or Automation with Touch is implemented in the Toyota Production System. Machines automatically stop production as soon as an error is detected.
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Visual Control An Understanding Examples of visual controls: What is Andon ?

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As machines had the capability to automatically stop production a single operator may visually monitor multiple machines. Toyota plants pioneered the use of a display board system to highlight a problem on the line; this is an Andon board.

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Advantages and Limitations

Advantages:
1. 2.

3.
4. 5.

6.

Information is easily and quickly understood. Corrective and Preventive actions take lesser time. Increases awareness of supervisory and control personnel. Transparency in working. Attacks lead time, easy inventory management and simplifies line monitoring. It infuses a sense of pride and self confidence.

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Advantages and Limitations

Limitations:
1. 2. 3. 4.

People tend to hide the facts if something goes wrong. Detailed information is difficult to display. Improperly designed visual displays may lead to a breakdown in communication Improperly designed displays may also be a distraction.

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Conclusion
The Essence 1. Workplace is able to speak with the help of visual displays. 2. If practiced systematically, will help implementation of JIT, TQM and SCM The Role 1. Speeds up non verbal communication 2. Opens up new avenues for improvement and moral boosting.

3. Makes work safer and easier.

Requirements 1. High levels of Motivation 2. Managements willingness to openly display information

Limitations 1. Require properly designed displays

2. High levels of detail are difficult to portray.

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Questions ?

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