Welcome to

Neville-Clarke Training On

Introduction of Visual Control

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Course Objectives

To gain the understanding of the following :

What is visual control
What it the benefit of visual control
How to develop a visual control

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Course Topics

Session 1 What Is Visual Control

Session 2 How to develop a visual control
Session 3 Sample of visual control application and
what is behind this control
Session 4 Workshops on Visual Control

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Session 1

What Is Visual Control

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Visual Control - Definition

A Surveillance control that uses a visual device which can

reveal at a glance, the normal or the abnormal status of
the Equipment operation or human behavior

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What is a visual control

Visual control is a control methodology

using visualization so we can understand
the control condition at a glance
It is about 10000 (or may be more)
control points in the factory, including
quantity of WIP, Finish products , RM,
pressure machines, location of tools,
location of pallets, Working instructions,
valves, thermometers, temperatures,
hoses, absenteeism's, customer complains
.
Visual control is a standardization method
on the 5S
We can Count at a glance
the quantity and condition
of tools

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Objective of Visual Control

To make an objects easy to observe, easy to understand

the condition

Which one is more easy to understand ?

Visual
Control

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Purpose of Visual Control System

TPM-AM (Support facilitation)

Easy to See
Easy to Understand
Easy to Tell
Easy to Know

Key point is TO MAKE A PROBLEM

VISIBLE by LOOKING AT A
GLANCE
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Where is Visual Control origin ?

Original From Japan

Meaning : Eyes Can see Control or only by our eyes

we can control any things

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Objective of Visual control

The objects are easy to understand by everybody so it is

easy to control by every body Multi Layer control

Gauge with operating range

: easy to understand by
everybody whether it is
normal or not

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 What is the Visual Factory ?
A Kan ban Board
show what
A visual factory is a factory, which its product, when and
control conditions are easy to catch, easy what Quantity
to understand and easy to control by every
one
It is easy to control because deploys 5Ss A communication
and visual control methodology board show
This visual factory is an ultimate target for QCDSM (quality,
5S implementation cost, delivery,
safety, and moral)
condition

A visual
factory shows
what product
being made,
who is made,
how is the
flow, how
much Qty,

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Session 2

How to develop a visual control

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Visual control object

Determine your control points

Is the object that we have to control because of several
reasons
This object is critical to product quality
This object is critical to process condition / machine condition

The only reason why we need to

control this gauge is because its
critical to product quality

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A Typical of Control Points

It is something that we have to control because of

particular reason, such as
On machines Gauges, equipment, panels, indicators
On materials materials condition, FIFO, Min-max
On Process Process performance or process
effectiveness

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Method of control

Method of control is shown by visual sign

Where is the working range. Such as gauge range, spec
and setting values
Where is the control position such as min max, FIFO
Where is the object position / placement such as a
yellow line, mould type storage.
Label indication by text , coloring etc

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Generating your idea

Visual control is about an idea how to make it easy to

control by visualize it

Controlling the gauge is more easy if

-Current reading is displayed
-Current setting is clear
-How much specification is clear
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Visual control is about creativity and
modification
A tools tray on this machine is dedicated
to this machine.
Easy to access
Easy to retrieve, return
Easy to control

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Visual control is about Creativity and
modification

Special tools
Easy to access
Easy to return
Easy to retrieve

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Session 3

Sample of visual control application and

what is behind this control

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Documentation System

Documentation system
Clear Indexing
Clear positioning
Clear Retention time

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Stationary System

Minimum use of stationary

Compact
Easy to retrieve, return

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Instrument

Visual control for gauge and instrumentation

Control point is
1. Setting value
2. Current value
3. Standard value

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 Visual control on whole machine
Similarity control on every
machine.
Makes easy to understand the
condition
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 Information board is media for understand the current condition. Is it
controllable or not
Production info
Productivity
Kaizen
Campaign
Etc

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 Andon for controlling the current operation. By define the
meaning in andon, we could understand whether the
machine is running or not

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Tools

Tools control points

Easy to access, retrieve, return
Easy to counting
Easy to maintain

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Visual Control for Autonomous Maintenance

Autonomous Maintenance
Improve maintainability by modify and visualize the
machine

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Visual control for autonomous maintenance

Control point is identified by Control

point numbers
Each control point is identified by visual
control

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Section 4

Visual Control Workshops

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Visual Control Workshops

Go to Gemba and See the actual condition

Search / determine the control point
Take photo
Plan for visual control

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Workshops activity sample on Visual Control

Determine the control point, give it control value

and take a photograph

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Course Summary

Visual control is a method of controlling a control point by

visualize the control points itself
Visual control is to make us easy to understand what the
control points, and how to control it
Visual control is very helpful if we need to control an
environment

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