TPS Principle 7 Use Visual Control So No

TPS Principle -7 Use Visual Control So No Problems Are Hidden. ADVIK CORPORATE - HR 1

TPS Principle -7 Visual controls Toyota Focus Organizational Benefits HIP Status ADVIK CORPORATE - HR 2

TPS Principle -7 Visual controls • • What are Visual controls ? Visual controls are basic indicators which gives information / status of the process, product, system and business parameters. Examples. Visual controls can be in any form like Physical, Soft forms etc. The examples are display boards, charts, andons, photos, smiley, tables etc. There are many more examples in our day today life. Traffic signals and signage. It is well designed visual control, their meaning are immediately clear. Signage on Highways, hospitals, safety displays at organizations, airport and rail signaling systems. Purpose – Safety, Clean it up, make it visual, Value additions. ADVIK CORPORATE - HR 3

TPS Principle -7 – Work Place Management System – 5 S • Seiri ( Sort) - Sort through items and keep only what is needed while disposing of what is not. Examples unwanted/scrap item disposals. • Seiton ( Straighten-orderliness) - A Place for everything and everything at its place. Work place orderliness and Management. Example- shadow tool boards. • Seiso ( Shine-cleanliness) - The cleaning process often act as form of inspection that exposes abnormal and pre-failure conditions that could hurt quality or cause machine failures. Examples- PM on machines, periodic cleaning. • Seiketsu (Standardize- create rules) - Develop procedures and systems to maintain above 3 S. • Shitsuke (Self discipline-sustain) - Maintaining the stabilized work place is an ongoing process of continues improvements ADVIK CORPORATE - HR 4

TPS Principle -7 – Work Place Mgmt System – 5 S Sort- Clear out rarely used items by red tagging Sustain. Use Reg. mgmt audit to stay disciplined Standardize Create rules to sustain 3 S Straighten – Organize and label place for Everything. Shineclean it Eliminate waste – 5 S cycle ADVIK CORPORATE - HR 5

TPS Principle -7 Toyota Focused visual controls § Visual controls are communicating devices used in the work environment to show work to be done and whether it is deviating from standard. § Visual controls systems are about improving value added flow. - status of work in process - Procedures for work - JIT system design - Process/material flow § Visual controls goes beyond capturing deviations from goals on charts and posting publicly… surface the problems. § Visual controls at Toyota are integrated into process of value added work. Set of equipment, procedures used, inventory & information can easily accessed and used at shop floor. § Min. and Max level of inventories can easily seen and monitored to keep lines running. ADVIK CORPORATE - HR 6

TPS Principle -7 Toyota Focused visual controls §Value Added Flow - Visual control to improve flow - Deviations from std. should be deviations from working to takt time. - Visualize any deviations from std. to facilitate flow. §Kanban - To control & manage inventories - Just in time - No overproduction - low cost §Andon - To detect and understand deviations from std. work - Jidoka - No defect passing to next process. ADVIK CORPORATE - HR 7

Organizational Benefits §Eliminate deviations from Std. work §Visualize/Surface the problems §Work place management §Safety §Value added work flow §Low cost on Inventories and mfg §Minimize waste and non value added activities §Cleanliness §Information sharing §Creating awareness §Adhere to std. procedure and systems §Improves OEE ADVIK CORPORATE - HR 8