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Mod 10 – Visual Control
10 Visual Control v20130529 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply
Global Production System
Product/Patient Quantity Analysis
Kaizen Kaikuku
Just-in-Time
Measures
Standard
Operations
Heijunka
(Leveling)
Continuous
Flow
Total
Productive
Maintenance
Poka-yoke (mistake
proofing)
Kanban
Setup Reduction
Changeover
Multi-process
Operations
Jidoka (human
automation)
GPS
MUDA MUDA
Visual
Control
Andon
TAKT TIME ONE PIECE FLOW PULL PRODUCTION
R
e
d
e
p
l
o
y
m
e
n
t
Committed Leaders
Profit =
Price - Cost
TAKT Time Map
Capacity Tables
Cost Reduction By Eliminating Waste
GPS Depth Study
NVA/VA-
Functions/Mgrs
Quality Cost Delivery
Morale Safety
Value Stream Mapping
5S • Sorting
• Simplifying
• Sweeping
• Standardizing
• Self Discipline
3P Prod Prep
7 Flows Medicine
7
Wastes
RPIW
7 Flows
Factory
4 No’s
© 1996-2013, John Black and Associates LLC
(modified from Hiroyuki Hirano, Productivity Press).
Visual
Control
Module 10
Mod 10 – Visual Control
10 Visual Control v20130529 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply 2
Visual Control: Key Points
Visual Controls are a tool to understand what is happening in
the workplace and a way to achieve zero defect quality.
Visual Control helps organizations respond quickly and
effectively to problems by making abnormalities and waste
obvious to everyone.
Visual Control tools and methods are JIT’s way of
“standardizing” management.
Andon (alarms) illuminate workplace problems.
Production management boards provide daily or hourly
information on current conditions.
Visual controls only make abnormalities visible. It’s up to
people to take corrective action – this is when Visual Controls
become Visual Management.
Mod 10 – Visual Control
10 Visual Control v20130529 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply 3
The Visual Workplace
Visual Controls
Workplace Organization (5S)
Visual Management
Mod 10 – Visual Control
10 Visual Control v20130529 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply 4
Purpose of Visual Controls
How can organizations keep pace with the
daily process improvements?
Learn to distinguish promptly between what is normal and
what is not with visual controls.
Make abnormalities and waste obvious enough for anyone
to recognize, constantly uncovering the need for more
improvements.
Help everyone to focus on finding the root causes of
problems and taking corrective action through improvement
work.
Visual Control leads to management by everyone since
problems and actions are made visible and team-based.
Everyone knows when there is a problem and what to do
about it.
Mod 10 – Visual Control
10 Visual Control v20130529 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply 5
Visual Controls
Tell at a glance what and how we are doing.
When someone walks into the workplace they should be
able to determine:
What the process is.
Who the customers and suppliers are.
What the deliverables are.
Where and what resources are being used in the
process.
That there is an effective measurement system in
place.
What the status of the process is.
Mod 10 – Visual Control
10 Visual Control v20130529 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply 6
Visual Controls
The KEY for making BOLD improvements
Make problems visible and obvious enough so that anyone can spot them.
Can you tell what the status of this Emergency Room is?
Who is in charge of what?
Mod 10 – Visual Control
10 Visual Control v20130529 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply 7
Types of Visual Control Description Illustration Name No.
1
2
3
4
5
Red tag
strategy
Signboard
strategy
White line
demarcators
Red line
demarcators
Andon
(alarm
lamps)
Red tag strategy distinguishes needed items from unneeded items in the workplace. Red tag teams use red tags to mark unneeded items for removal.
In the signboard strategy, set up signs that indicate what belongs where and in what amount, so that anyone will be able to understand where things belong.
When organizing the workplace, marking out pathways and in-process storage sites with white tape makes it easy for anyone to keep the workplace neat.
Red line demarcators form part of the signboard strategy. Mark the maximum allowable stack height with a red line to show when excess inventory exists. Think of the red lines in the OR that indicate where you need to stop.
Andon immediately alert staff to abnormalities that occur in the workplace – like an IV pump not working.
Mod 10 – Visual Control
10 Visual Control v20130529 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply 8
Types of Visual Control Description Illustration Name No.
6
7
8
9
10
Kanban
Production
management
boards
Standard
operation
charts
Defective
item
displays
Error
prevention
Kanban are administrative tools that maintain Just-In-Time production – part of the supply chain. The two types of kanban are pickup kanban and production kanban.
Display boards that indicate current conditions on production or service lines. Data shown on these boards include production/service line results, operating conditions, and causes for the process stopping – like bed control boards.
Use these charts to find the work methods that use the best combination of people, machines, and materials. Standard work charts should be posted where the work is being done.
Set up at workplaces where defects have occurred, these displays exhibit defective items along with graphic data urging staff not to allow the same defects to recur. Pictures work well to show defects too.
Error prevention boards help promote independent management to reduce human errors. Try to set up boards that allow staff to manage and correct themselves, or not do an error at all.
9
Mod 10 – Visual Control
10 Visual Control v20130529 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply
Primary Care Exam Room:
Each flag indicates a different room status
Used with permission/Seattle Children’s Bellevue Surgery Center
10
Mod 10 – Visual Control
10 Visual Control v20130529 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply
Used with permission/Seattle Children’s Bellevue Surgery Center
11
Mod 10 – Visual Control
10 Visual Control v20130529 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply
Used with permission/Seattle Children’s Bellevue Surgery Center
12
Mod 10 – Visual Control
10 Visual Control v20130529 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply
Used with permission/Seattle Children’s Bellevue Surgery Center
RPIW Audit Metrics (mostly green)
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Mod 10 – Visual Control
10 Visual Control v20130529 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply
RPIW Audit Schedule
Used with permission/Seattle Children’s Bellevue Surgery Center
Mod 10 – Visual Control
10 Visual Control v20130529 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply 14
Anesthesia
“Shadow
Board”
14
Before
With visual control it is obvious if
anything is missing Used with permission/Virginia Mason Medical Center
Visual Control
Mod 10 – Visual Control
10 Visual Control v20130529 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply 15
15
Used with permission/Ministry of Health, Saskatchewan Province
Visual Control
Mod 10 – Visual Control
10 Visual Control v20130529 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply 16
16
Standard work chart
Used with permission/Ministry of Health, Saskatchewan Province
Visual Control
Mod 10 – Visual Control
10 Visual Control v20130529 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply 17
17
Used with permission/Ministry of Health, Saskatchewan Province
Visual Control
Mod 10 – Visual Control
10 Visual Control v20130529 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply 18
Types of Andon
Andon (alarms) alert staff and leadership to problems on the
hospital or clinic floor.
Andon are signals that illuminate problems in the workplace.
The types of Andons are:
• Paging
• Emergency
• Operation
• Progress
Mod 10 – Visual Control
10 Visual Control v20130529 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply 19
Types of Andon Paging
Alerts staff responsible for stocking that supplies are needed.
Emergency
Alerts staff and leadership that a problem has occurred, and brings
leadership immediately to the location to resolve the issue. Patient safety
alert/stop the line is an example of this andon.
Operation Indicates machine operating status, such as an IV pump, X-ray machine, or
a printer. When the machine has been stopped, the operation andon
shows the reasons for the stoppage.
Progress Enables staff to gauge the progress of their own operations and
processes.
Mod 10 – Visual Control
10 Visual Control v20130529 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply 20
Production Management Boards
At-a Glance Supervision
Production management boards should be simple in design and emphasize information that answers the following key questions:
How do current results compare with estimated results?
Why was the line stopped the last time?
What kind of improvement is needed?
Will there be any spill-over into overtime or tomorrow’s schedule?
Mod 10 – Visual Control
10 Visual Control v20130529 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply 21
Production Management Boards
At-a Glance Supervision
Production management boards aren’t just for managers. The people on the hospital or clinic floor – anyone doing work, as well as the workplace leaders - need production management boards to keep them informed. Hint: Post the production management boards as “the final process” in the line, so that everyone checks it at least once per work cycle, and knows the process status.
22
Mod 10 – Visual Control
10 Visual Control v20130529 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply
Used with permission/Seattle Children’s Bellevue Surgical Clinic
Production Board
23
Mod 10 – Visual Control
10 Visual Control v20130529 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply
Used with permission/Mayo Clinic
Production Board – Real-Time Tracking of
OR Patients in Surgery
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Mod 10 – Visual Control
10 Visual Control v20130529 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply
25
Mod 10 – Visual Control
10 Visual Control v20130529 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply
Mod 10 – Visual Control
10 Visual Control v20130529 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply 26
Relationship between
Visual Control and Kaizen
No matter how many visual aids are brought into the
organization, they are not valuable if they are not used
correctly to discover and promptly correct abnormalities.
Remember that introducing visual control tools will not
automatically result in improvements.
Visual control tools only do one-third of the job – they
help make abnormalities easier to discover.
People must do the other two-thirds – analyzing the
abnormalities and taking corrective action. This is visual
management.
27
Mod 10 – Visual Control
10 Visual Control v20130529 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply
The Role of Visual Control Tools in the
Improvement Cycle
Abnormality
Occurs
Standardize
Improvement
Make
Improvement
Look for Cause
Right Away
Discover
Abnormality
Visual
Control Tools Improvement
Cycle =
Visual Control
1.
2.
3.
4.
5.
6.
Mod 10 – Visual Control
10 Visual Control v20130529 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply 28
Visual Control Summary
Visual control makes the organization’s abnormalities
and waste so clear anyone will recognize them.
Visual Control leads to management by everyone by
making problems and actions transparent.
Visual Control is JIT’s way of standardizing
management.