Shortcuts & Tips

for a Visual Workplace

 What is the Difference?

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!

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 Lean Manufacturing

Many tools, one common goal…eliminate waste!

 Look closely and you will see that these are all
visual tools!

Visual
Workplace

Value Stream 5S
Mapping

Standard Kanban
Six-Sigma
Work

Total Quick Heijunka

Error Productive Changeover
Proofing Maintenance

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 What is a Visual Workplace?

A workplace that speaks for itself and engages

employees to expose problems and solve them by:
 Identifying abnormal situations
 Directing behavior
 Eliminating missing information

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 A Road Map for a Visual Workplace

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.

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 A Road Map for a Visual Workplace

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

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 Missing Information

ELIMINATE
MISSING INFORMATION…
AND YOU WILL ELIMINATE WASTE!

What does missing information look like?

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 Missing Information

Is there too much inventory here or is it stacked too high?

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 Missing Information

Are your tools where they should be?

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 Missing Information

Where do the broom & dust pan belong?

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 Missing Information

What is supposed to happen here?

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 Missing Information

Cluttered bulletin boards with old information that are not

standardized.

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 Missing Information

How do you find something quickly?

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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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 Missing Information

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

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 Visual Workplace Shortcuts

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.

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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 Adhesive Labels

Magnetic labels are more flexible for making location changes

and last longer than 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

“Your Mother don’t work here so clean up

your mess! Thanx”

What is more effective? Avoid hand-made signs. They do not

have the same impact as a professional sign.

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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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 Visual Workplace Shortcuts

Conduit can also be used to create a frame. Attach signs to

the frame using Velcro.

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 Visual Workplace Shortcuts

Create shadow boards for 5S cleaning supplies to reduce time

spent searching.

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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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 Visual Workplace Shortcuts

Color code whenever possible to reduce risk of error.

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 Visual Workplace Shortcuts

– This sign is 24”

tall and should
not hang any
higher than 24 24” high
feet off the
ground

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.

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 Visual Workplace Shortcuts

Replace painted tool boards with custom cut adhesive vinyl

for each shadow.

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 Visual Workplace Shortcuts

Create professional tool

shadow with Shadow-Mark!

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 Visual Workplace Shortcuts

Detail what is required, to know what is missing.

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 Visual Workplace Shortcuts

Add an address label to the item AND the location to ensure

proper placement.

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 Visual Workplace Shortcuts

Use visual scoreboards for training matrices instead of keeping

them on a spreadsheet.

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 Visual Workplace Shortcuts

Gauge Mark
 Create at-a-glance process controls!
 It can be applied to gauges and other
inspection tools used for measuring and
controlling processes.

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 Results of a Visual Workplace

What can you expect?

15% Throughput
70% Material Handling
60% Space
50% Inventory
20% Machine Utilization

You Won’t Get LEAN…

Until You Get Visual!
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If you are interested in learning how to make
your own visuals and signs, please contact us.
www.visualworkplaceinc.com
616-583-9400
[email protected]

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