Visual Operations Control Kaizen Objectives:
- Familiarize kaizen team members with just-in-time visual operations management principles & methodologies
- Assist kaizen team members in "visually seeing the flow of work" through their operations
- Create a comprehensive diagram of current state operations management & control processes and customer requirements flow
- Assist kaizen team members in understanding how lean principles can significantly improve operations management and control processes
- Assist team members to visualize, then develop an effective visual just-in-time production control system using visual control boards to enable balance & flow in operational activities
To achieve these objectives, kaizen team members will:
- Practice, through discussions and case study illustration, traditional operations management systems, visual operations management concepts, and team building
- Develop an aggressive, yet effective future state operations management system and visual procedures
- Define operations management & control performance measurements indicators and roles and responsibilities
An operation's management & control system is the heart and sole of the operation and involves all activities necessary to plan, prioritize, resource, initiate, control, adjust, realign, and orchestrate the accomplishment of customer's requirements.
Each activity in this management and control process is either value adding (e.g., Maintaining work balance) or non-value adding (e.g., Recovering from a sequencing error). "Visualizing or seeing" your operational system's flow from a customer value chain perspective means looking at every stage in terms of the value it adds in providing customer value. It means paying attention to improving the operations management system as a whole. From customer need to delivery of the product or service.
By creating a current state map (how we manage operations now) you create a "visual" of operational flow. From this baseline, you can apply lean principles to create an improved future state operations management system (how we want to do it) vision and how it will operate.
Analyzing & improving operations management & control techniques through flow kaizen methods is a simple process. You map current systems & processes through interviews, observation and by following customer requirements through the system, carefully drawing a visual portrayal of each stage in the flow and documenting activities and decisions occurring at each of these stages.
Results will be enlightening, revealing problems and potential solutions and opportunities where integration of lean principles will harvest significant improvements in operations management and control. Then those improvements can be systematically implemented to improve the entire system.