Managing Director Tim McLean explains the different types of visual controls you can implement Visual Controls Visual Management and Visual Controls go hand in hand they are the life blood of a Lean production system Visual Management is designed to create a visual workplace with controls communicating without words and interruptions in process Visual Controls have the potential to help identify problems reduce waste reduce production costs shorten lead times reduce inventory create a safe working environment and even increase your profits Visual Controls standardise decision making based on facts For example if the light is red I can not go if it is green I can The color of the traffic light is a fact that allows us to make a decision to go or to stop our car Likewise visual controls give us the ability to tell normal from abnormal right away So to extend the analogy the car going through the red light is clearly abnormal whereas a flow of traffic on a green light is normal In fact visual controls are everywhere in our everyday life from market car spaces to colour coded subway lines and green emergency exit signs Unfortunately we step in to our workplaces these useful codes to direct our behaviour tend to disappear and we are faced with ambiguity everywhere Visual Controls can be used across your business are are equally effective in the office operations or engineering Visual controls can also be powerful in maintaining quality and safety There are a variety of different visual controls you can implement to create an environment in which the non-standard can be distinguished from the standard Below is a summary of some of the more widely seen visual controls our consultants see out in the field Color Coding The easiest form of visual controls to apply is color coding where we use colors to communicate status Once implemented it allows employees to easily identify what action to take next Having color-coding standards in your workplace will help ensure a uniform style across the business Color coding can be applied to all departments including color coding shadow boards for tools color coding floor markings even office documents Another tool that can be used is a color-coded visual board These boards are updated on a regular basis provide instructions on everyones tasks in the workplace Implementing a color-coded visual board can help employees keep track of their work tasks Andon Andon refers to a system that provides notification to management maintenance and operators of a quality or process problem It works when an issue is found at a process the team member has the ability to immediately notify support staff so that the problem can be managed In manufacturing it allows a worker to stop production when a problem is found and immediately call for assistance This can be extended to an office process where raising an Andon flag means that the process does not go on to the next step until the issue is resolved The Andon can be triggered manually by using push button pull cord or even flags The common reasons for activating the Andon can be part shortages defect created or found tool machine malfunction or the existence of a safety problem Standard Work Often there are always several ways to do a task but only one of these ways is the most efficient use of resources based on current knowledge Over time the skills needed to perform a task can become lost and the process of relearning is repeated Standard Work provides employees of all levels with structure and predictability to their working week to enable them to maximise their efficiency and impact The process of developing standard work ensures that employees understand all of their must do tasks and allocates the most appropriate time to complete these tasks In the Toyota Production System there are four aspects to standardisation Content this is agreeing the steps that are involved in the task Sometimes there is debate as to whether particular steps are necessary To develop standardised work the team must agree what the necessary steps are Sequence the steps must be completed in the same sequence every time This is essential to ensure a consistent outcome Timing there should be a standard time that it takes for a trained person of average competency to do the task Knowing this standard time enables us to balance that task with other tasks to create level production Outcome the outcome of the task needs to be clearly defined in terms of quality safety and output The Standard Work approach is established so that it is practical and useful to everyone and free of difficulty Standard Work is not perfect and is considered a living document that develops over time But remember standard work will die very quickly if it is ignored Examples of Standard Work Work instructions at each work cell allowing operator and production change overs to be an easy transition Standard work sheets with instructions and diagrams for manufacturing processes Floor Line Marking Signage Floor line marking and signage showing pathways vehicle lanes working cells and intersections These consist of colour coded floor markings signage with different logos and markings to make these easily and quickly identifiable Floor markings and signage as visual controls outline where materials people flow should end up reinforcing a safety culture without interruption to the manufacturing process Visual Boards Visual boards are used to promote Plan Do Check Act The boards work when the first shift starts the production plan is established at a stand-up meeting At every change over the production for the day is tallied on the board and any problems are action-ed by the supervisor to recover production at the next change over Visual boards come in a variety of shapes and sizes they can be used across the business in all departments not just limited to the factory floor In the office visual boards can be used for projected sales targets actual sales targets quoted projects and even the mood of employees Quality Standards Having quality standards for products helps to give your operators a visual control to base their decisions off when determining quality These standards should be in reach of operators for easy reference Visual Controls when applied to quality help to reduce defects and eliminate quality control inspection from your process There are a variety of visual controls you can introduce into your organisation to support your visual management goals Visual controls are used to help your organisation see the wastes shorten time to find out information materials and promote a Plan Do Check Act culture of Continuous Improvement