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IMPORTANCE OF VISUAL CONTROL: LEAN MANUFACTURING SERIES
The use of visual controls is the most important step in the process of developing standardization. Unfortunately, it is also the aspect of a lean process that is most often belittled. We frequently hear, “They are just doing 5S.” Perhaps this is due to the examples of visual control most often cited, namely, markings on the floor to indicate the location of trash containers and other items in the work area, which are viewed as “silly” and perhaps insulting to the intelligence of employees. Another example is signs that are used to identify the proper location of items or the type of material stored in a location. Managers and employees
often respond with, “We all know what belongs there.” However, when asked to identify specific conditions such as the standard quantity, the minimum or maximum, or the supplying operation, the response is usually less certain.
Figure demonstrates that the primary reason for visual control is to define the desired “normal” state (standard), and then to quickly recognize any deviation from that standard. As we have seen, there are many different specifications, procedures, and requirements within every work area. It is virtually impossible for every employee to remember all of these, and a written description of each in a notebook would be impractical for instant recognition.
One common condition is that people believe they “know” the standards, and any visual representation is redundant and unnecessary. Upon closer evaluation it is simple to determine the true awareness of standards. Ask different employees to explain the specific method to be followed. Is it possible for you to determine whether it’s happening as it’s supposed to be? The case example below on paint line loading illustrates that without the ability to quickly and easily verify adherence to standards, the abnormality will not be detected and will continue.
often respond with, “We all know what belongs there.” However, when asked to identify specific conditions such as the standard quantity, the minimum or maximum, or the supplying operation, the response is usually less certain.
Figure demonstrates that the primary reason for visual control is to define the desired “normal” state (standard), and then to quickly recognize any deviation from that standard. As we have seen, there are many different specifications, procedures, and requirements within every work area. It is virtually impossible for every employee to remember all of these, and a written description of each in a notebook would be impractical for instant recognition.
One common condition is that people believe they “know” the standards, and any visual representation is redundant and unnecessary. Upon closer evaluation it is simple to determine the true awareness of standards. Ask different employees to explain the specific method to be followed. Is it possible for you to determine whether it’s happening as it’s supposed to be? The case example below on paint line loading illustrates that without the ability to quickly and easily verify adherence to standards, the abnormality will not be detected and will continue.
40 pages, Kindle Edition
Published May 12, 2017
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