Workplace Organization (WPO) and Visual Controls (VC)

Two closely aligned techniques which complement one another and are often implemented together. –To show the importance of simple waste elimination tools –To show the significance of eliminating anything not required –To support the facility with easily understood “signals” that provide instruction –To learn how signals can indicate if a normal or abnormal condition exists in a process Purpose of WPO and VC

Workplace Organization (WPO) Definition: A safe, clean, neat arrangement of the workplace which provides a specific location for everything, and eliminates anything not required. “A place for everything, and everything in its place.”

Workplace Organization A Waste Elimination Tool Parking Lot INOUT Desk Tool Board

Workplace Organization A Waste Elimination Tool Steps in implementing WPO: 1Clear 2Organize 3Clean 4Maintain 5Create Pride

Workplace Organization A Waste Elimination Tool Step 1:CLEAR workplace Remove all un-needed items such as: -Racks -Tools -Containers -Equipment -Excess Materials

Workplace Organization A Waste Elimination Tool Step 2:ORGANIZE what’s left Everything has a place, everything in its place Variety of ways to designate locations: -Lines on the floor -Signs hung from the ceiling -Tool boards

Workplace Organization A Waste Elimination Tool Step 3:CLEAN-UP what’s left Paint, refurbish, etc. Get the remaining items into the same condition as when they were new!

Workplace Organization A Waste Elimination Tool Step 4:MAINTAIN “like new” organization Develop procedures that can keep things “like new” (i.e., housekeeping & preventative maintenance) Assign responsibilities to apply these procedures Get affected workgroup to make sure procedures are being utilized

Workplace Organization A Waste Elimination Tool Step 5: Create PRIDE in the workplace and the discipline to maintain it Formalize Practice continuously

Visual Controls (VC) Definition: Simple visual and audio signals that provide an immediate understanding of a situation or condition. They are efficient, self regulating, and worker managed.

Visual Control A Waste Elimination Tool Both Audio & Visual Controls

Visual Controls A Waste Elimination Tool Visual Controls should be designed to quickly provide useful information. Visual Controls should be developed to identify, instruct or indicate either a normal or abnormal condition. Visual Controls should make the workplace “talk” to you.

There... that should clear up a few things around here!! Visual Control, not Visual Clutter ! Garage Shrubs Roof of House House Grass Door

Workplace Organization & Visual Controls Benefits: Improves quality Reduces cost Improves responsiveness Improves safety

Key PointObservations Visual Control (Status at a glance) Audio Control (Understandable) Workplace Organization (Everything in its place) Boundary Samples (Good vs. bad) Process Control Manual & Automatic (Bad parts not passed on) Facilities / Equipment (Layout “U” cells) Flexible System (Quick setup & change capability) Decoupled Process (Stop part, but not all of line) Knowledge by Walking Around Observation Worksheet: Workplace Organization & Visual Control