What is visual control?

Visual control methods aim to increase the efficiency and effectiveness of a process by making the steps in that process more visible. The theory behind visual control is that if something is clearly visible or in plain sight, it is easy to remember and keep at the forefront of the mind. Another aspect of visual control is that everyone is given the same visual cues and therefore are likely to have the same vantage point. There are many different techniques that are used to apply visual control in the workplace. Some companies use visual control as an organizational tool for materials. A clearly labeled storage board lets the employee know exactly where a tool belongs and what tools are missing from the display board. Another simple example of a common visual control is to have reminders posted on cubicle walls so that they remain in plain sight. Ongoing processes are commonly made visible by LED displays, colored, lights, computer images, etc. Any device that is designed to give these visual cues in conjunction with visual control is called an Andon board.

Visual signs and signals communicate information that is needed to make effective decisions. These decisions may be safety oriented or they may give reminders as to what steps should be taken to resolve a problem. Most companies use visual controls in one degree or another, many of them not even realizing that the visual controls that they are making do in fact have a name and an obvious function in the workplace. Whether it is recognized by the name of "visual control" or not, the fact is that replacing text or number with graphics makes a set of information easier to understand with only a glance, making it a more efficient way of communicating a message.

What are visual controls meant to do?

Visual controls are designed to make the control and management of your company as simple as possible. This entails making problems, abnormalities, or deviations from standards visible to everyone. When these deviations are visible and apparent to all, corrective action can be taken to immediately correct these problems. Visual controls are meant to display the operating or progress status of a given operation in an easy to see format. Furthermore visual controls are meant to both provide instruction and to convey information. A visual control system must have an action component associated with it in the event that the visually represented procedures are not being followed in the real production process. Therefore visual controls must also have a component where immediate feedback is provided to workers.

Visual control, although very commonly associates with Lean Manufacturing techniques, is not limited only to production line processes. Visual control can be used with all sorts of management techniques and other tools for implementing procedures to make the workplace run more efficiently. Here are just a few examples of the more common associations of visual control with other tasks around the workplace:

• Combining the use of visual controls with the 5S process (to be discussed in more detail a little later in this article.)
• Using visual control in operations, engineering, management, maintenance and quality assurance.
• Having visual controls assist in the issuing of safety warnings and rules pertinent to specific working environments.

Of course this is by no means an all inclusive list of the possible applications of visual controls, but hopefully it gives you a good idea of what areas of your workplace could possibly benefit from a more focused visual control approach.

Benefits of visual control

The whole purpose behind implementing visual control techniques is to expose abnormalities in the production line that could ultimately end up costing the company money or create waste. When visual control is able to do a good job at helping employees to recognize these abnormalities action can be taken to correct the problems, reduce manufacturing costs, reduce possible waste, shorten production lead time and thus keep the delivery due dates, reduce inventory, ensure a safe and comfortable working environment, and increase the company's profit. Visual control systems are implemented with the expectation that thousands of location and operation details can be managed visually thus aiding the growth and quality of the company for which those visual controls were created. An added benefit to visual control systems is that many of the visual controls used eliminate the need to verbally communicate a need. Instead needs and expectations are clearly displayed, eliminating the time often wasted on the confusion of miscommunication due to different methods of verbal communication. With visual controls you can potentially create an atmosphere of production that is self-regulating and self-explanatory. Employees are happier because they understand clearly what is expected of them and managers/owners are happy because all employees remain on the same page. Customers are ultimately the beneficiaries of such efficiency when they consistently receive a high quality product. Visual control guidelines

As you begin to brainstorm about how you will approach the implementation of your visual control methods, keep in mind that the main purpose of visual control is to organize the working area so that all people (employees and visitors alike) can tell whether things are going as they should or if there is a problem occurring. These factors should be clear as they stand as in there should be no need for professional help in determining how things are running because your visual control system is that clear. Usually there are two types of visual control implementation items they are actual or analog. Examples of actual items that can be implemented through visual control are items that are designed to designate a location/position for each item, indicate quantity including inventory levels, distinguish items from each other and specify form. Analog items that can be implemented through visual control are seen in the following examples: colors, shapes, symbols, characters, numbers, graphs, electronic lights, sound, touch, smell, taste, etc.

Steps needed to implement a visual control procedure

Implementing a visual control procedure is going to involve elements of planning, action and checking. Although there is not necessarily a single method of implementation that is right while other methods are wrong, the following steps are quite effective and are used effectively by many companies who follow them.

The first step that may be taken in the implementation procedure for visual control is to organize a program committee who will be responsible for developing a plan and a budget for that plan. Examples and cases will need to be collected and personally applicable examples developed. Once the program is developed an announcement and introduction as to the start of the program needs to be announced. Naturally employees will need at least some training and support until they can be comfortable with the new process. Once everyone feels comfortable with the training that they have received a day is chosen when the new procedures will be implemented in various specific working areas. After closely observing the actual application of the visual control plan, evaluations need to be made regarding its effectiveness and corrective actions need to take place if there are inefficiencies.

Visual control and 5S

Visual control and 5S are frequently mentioned together mainly because the need for visual control is so often the result of wanting to effectively implement a sustaining 5S method of production. As a quick review, the 5S's stand for sort, set in order, shine, standardize, and sustain. These five elements are also referred to as the five pillars of the workplace and are simple activities that are often difficult to implement. To often managers assume that to make big differences in their methods of production, elaborate plans of implementation and maintenance are needed. However, experience has shown that companies that use pictures and illustrations (visual controls) to implement these five principles find that the transition in implementation is simpler and that the maintenance of the new method of waste reduction remains efficient for a longer period of time.

The whole point of visual control is that it is used to better implement other procedures that may otherwise be too tedious or complicated to understand. The principles of Lean Manufacturing are not strange or unusual but to a company who has been producing a product the same way for many years, change can come as quite a shock. Implementing visual controls to help aid in the implementation process, enhances those innovative processes and allows them to better enhance the overall efficiency of the company.

What is Kanban?

Kanban is a term that is sometimes used in conjunction with visual control. In fact, the word "kanban" directly translated from Japanese means "visual card" or "visual board." Kanban has historically used cards to signal the need for a movement, production or supply of an item in a factory. The Kanban system was developed by the Toyota Corp. and was designed to fill the need for a method of maintaining the level of improvements that a company was in need of by highlighting problem areas.