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 – 5S
• 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 3S.

• 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 – 5S

Sort-
Clear out rarely
used items by red tagging

Sustain-
Use Reg.mgmt audit to
stay disciplined
Straighten –
Organize and label place for
Everything.

Standardize
Create rules to sustain Shine-
3S clean it

Eliminate waste – 5S cycle

ADVIK CORPORATE - HR 5
 TPS Principle -7 Toyota Focused visual controls
 Visual controls are communicating devices used in the work environment
to show how 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