TQM CONCEPTS

 

Visual Control

Visual control is one of the important concepts related to Total Quality Management. It was developed in Japan in the 1960’s. Visual Control emphasized the importance of surfacing defects and abnormalities in either the product or process in such a way as to be visible to the operator or supervisor so that immediate corrective action could be taken. This was in sharp contrast to the earlier practice of punishing workers for mistakes which in turn led them to hide their mistakes. The key features of Visual Control were:

  • make the problems, abnormalities, or deviation from standards visible to everyone and thus corrective action can be taken immediately,
  • display the operating or progress status in a easy to see format.
  • provide instruction.
  • convey information.
  • provide immediate feedback to people.

Various means were used to implement this concept such as the use of alarms, flashing lights, odors, visual representations such as graphs & control charts, diagrams, etc. to bring the defect or abnormality to the notice of employees. Visual control can also be used in service organizations depending on the situation. It can be used by all functions such as production, maintenance, quality, HRD, Finance, Safety, etc.

Potential Benefits of VC

Implementing VC in the plant would help the companies to exposing abnormalities, problems, deviations, waste, unevenness, and unreasonability to people, thus corrective actions can be taken immediately to:

  • correct the problems,
  • reduce manufacturing costs,
  • reduce possible waste,
  • shorten production lead time and thus keep the delivery due date
  • reduce inventory
  • ensure a safe and comfortable working environment.
  • increase company's profit.

Guidelines for Practicing Visual Control

The main purpose of visual control is to organize the working area such that people (even outsiders) can tell whether things are going well or are amiss without the help of expert. Visual control can be implemented using either the actual or analog items.

Actual Items:

  • Designate a Location (position) for each item.
  • Indicate Quantity (eg. a two bin system).
  • Distinguish Item from each other by color codes/ shapes/ design.
  • Specify Form (Document).

Analog Items:

  • Colors.
  • Shapes (Contour).
  • Symbols.
  • Characters (Verbal).
  • Numbers.
  • Graphs.
  • Electronic Lights.
  • Sound.
  • Touch.
  • Smell.
  • Taste.

Implementation Procedure of VC

The PDCA cycle and suggestion schemes provide some of the best frameworks for implementing Visual Control. However in some cases these methods are implemented by the management on its own or under the guidance of TQM consultants. Visual Control is also used extensively by Quality Circles and 5S programmes.