shortcuts & tips for a visual workplace...5s & visual workplace are not the same! it is...
TRANSCRIPT
Shortcuts & Tips for a Visual Workplace
www.visualworkplaceinc.com
5S & Visual Workplace are not the same! It is important to understand the differences
between 5S and Visual Workplace. Both are effective tools utilized within a Lean
environment. When applied independently, they both yield very
distinctive but remarkable results. • 5S organizes and defines the Where! • Visual Workplace defines Who, What, When
How and Why!
What is the Difference?
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Many tools, one common goal…eliminate waste! Look closely and you will see that these are all
visual tools!
Lean Manufacturing
Error Proofing
Total Productive
Maintenance
Quick Changeover
Heijunka
Standard Work Six-Sigma Kanban
Value Stream Mapping
5S
Visual Workplace
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A workplace that speaks for itself and engages employees to expose problems and solve them by:
Identifying abnormal situations Directing behavior Eliminating missing information
What is a Visual Workplace?
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Where do you begin? Start with 5S and organize your workplace
• Scan to see the process. • Sort to begin to expose waste in the process. • Simplify to begin to define abnormal
conditions. • Sweep to make the workplace cleaner, safer
and more productive. • Safety to respect people.
A Road Map for a Visual Workplace
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After organizing and removing unnecessary items, ask who, what, when and how.
Create standards for each element of your workplace and eliminate missing information. • Inventory • Process • Work Instructions • Scoreboards • Territories
A Road Map for a Visual Workplace
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ELIMINATE MISSING INFORMATION…
AND YOU WILL ELIMINATE WASTE!
What does missing information look like?
Missing Information
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Is there too much inventory here or is it stacked too high?
Missing Information
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Are your tools where they should be?
Missing Information
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Where do the broom & dust pan belong?
Missing Information
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What is supposed to happen here?
Missing Information
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Cluttered bulletin boards with old information that are not standardized.
Missing Information
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How do you find something quickly?
Missing Information
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Missing Information
Is this a standard procedure?
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Missing Information
Is this system obsolete? If so, why is it still displayed?
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Recognizing missing information is not easy You must teach your team to see missing
information Start by taking a walk to specifically look for
missing information for: • Inventory • Process • Work Instructions • Scoreboards
Take photos, share them with your team and teach them what to look for in their areas
Missing Information
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There are some simple methods that can be used to create effective messages.
This visual is clearly not focused on the most important message!
Use the following ideas and tips to teach your team how to create effective visuals and create your own benchmarks.
Visual Workplace Shortcuts
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Visual Workplace Shortcuts
Add controls behind work instructions.
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Visual Workplace Shortcuts
When the work instruction is missing the operator is instructed not to continue without it.
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Visual Workplace Shortcuts
Place work instructions directly at the point of use instead of in binders.
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Visual Workplace Shortcuts
Add work instructions to visuals identified in reverse so that you bring attention to what must be done.
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Visual Workplace Shortcuts
When defining areas, add the instruction to the visual display.
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Visual Workplace Shortcuts
Don’t assume they know what to do when they are done. Reminders are priceless!
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Visual Workplace Shortcuts
Add a document directly to the visual using adhesive pouches. See www.Rochester100.com for many different sizes.
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Visual Workplace Shortcuts
Color code inventory locations for more efficient material handling.
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Visual Workplace Shortcuts
Color coding can increase efficiency in many areas of your facility.
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Visual Workplace Shortcuts
Conduit and zip strips keep visuals at the same height easily instead of “S” hooks and chain for each sign.
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Visual Workplace Shortcuts
Consider using corners to mark the floor. Less material and labor are used with corners than with striping.
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Visual Workplace Shortcuts
Cover floor markings with clear adhesive vinyl to maintain appearance longer.
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Visual Workplace Shortcuts
Use colored 3mm PVC for Kanban boards instead of plywood which requires painting.
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Visual Workplace Shortcuts
Color coded flags can communicate inventory shortages without speaking.
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Visual Workplace Shortcuts
Use powder coated sheet metal for KPI boards when you only need magnetic application. Don’t pay for applications you don’t need.
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Visual Workplace Shortcuts
Add Min/Max requirements to inventory locations.
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Visual Workplace Shortcuts
This pyramid sign was added to the top of this storage unit to prevent tools from being placed here instead of in their proper
location inside the cabinet.
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Visual Workplace Shortcuts
Magnetic labels are more flexible for making location changes and last longer than adhesive labels.
Magnetic Labels Adhesive Labels
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Visual Workplace Shortcuts
Don’t forget to add the arrows!
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Visual Workplace Shortcuts
If you only need a dry erase board, don’t pay for a magnetic board too! We offer a dry erase board that is very inexpensive
and can be cut to size.
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Visual Workplace Shortcuts
A 4'x8' dry erase board is $49.95 instead of $300.00.
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Visual Workplace Shortcuts
Make your own banners and get your message noticed.
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Visual Workplace Shortcuts
What is more effective? Avoid hand-made signs. They do not have the same impact as a professional sign.
“Your Mother don’t work here so clean up your mess! Thanx”
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Visual Workplace Shortcuts
Professional looking visuals give your systems credibility!
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Visual Workplace Shortcuts
Can you navigate through your facility like an airport? Customers and prospects love the attention to detail!
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Visual Workplace Shortcuts
A PVC frame can be used to create Directory signage very inexpensively.
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Conduit can also be used to create a frame. Attach signs to the frame using Velcro.
Visual Workplace Shortcuts
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Create shadow boards for 5S cleaning supplies to reduce time spent searching.
Visual Workplace Shortcuts
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Visual Workplace Shortcuts
Magnetic Labels Buy magnet in 24” wide rolls and
cut them to size. Thin strips pre-cut can cost more
than $10.00 per square foot. You can save 65% cutting the
magnet yourself.
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Color code whenever possible to reduce risk of error.
Visual Workplace Shortcuts
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Beware of how high you hang your signs with respect to the size of the sign. Signs should be hung one foot off the
ground for each inch of height of the sign.
– This sign is 24” tall and should not hang any higher than 24 feet off the ground
24” high
Visual Workplace Shortcuts
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Replace painted tool boards with custom cut adhesive vinyl for each shadow.
Visual Workplace Shortcuts
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Create professional tool shadow with Shadow-Mark!
Visual Workplace Shortcuts
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Detail what is required, to know what is missing.
Visual Workplace Shortcuts
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Add an address label to the item AND the location to ensure proper placement.
Visual Workplace Shortcuts
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Use visual scoreboards for training matrices instead of keeping them on a spreadsheet.
Visual Workplace Shortcuts
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Gauge Mark Create at-a-glance process controls! It can be applied to gauges and other
inspection tools used for measuring and controlling processes.
Visual Workplace Shortcuts
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Results of a Visual Workplace
15% Throughput 70% Material Handling 60% Space
50% Inventory 20% Machine Utilization
You Won’t Get LEAN…
Until You Get Visual!
What can you expect?
If you are interested in learning how to make your own visuals and signs, please contact us.
www.visualworkplaceinc.com 616-‐583-‐9400
Click for con+nuous improvement ideas.