Color: A simple yet effective visual control tool

Color visual controls are considered a basic component of the Lean initiatives usually implemented through the application of the 5S strategy. The 5S, discussed in a previous post, is a methodology adopted by many big and small organizations, manufacturing and services alike, aiming reduce costs, eliminate wastes and achieving overall improvement. Among the steps followed through the 5S, one of the simpliest and yet very effective approches is color coding. Color based visual control tools are, if adequately implemented, one the fatest and clear ways to convey meaning and direction in the organization.

Although some color conventions have been defined as general practice, what is important is that the color coding that is used within the workplace is based on using specific standards for the company. Consistency the the key to send the message and it to be received and applied. Below are some color conding standard commonly used:

• Red bins/labels: used for defective products
• Green bins/labels: used for products that met quality control requirements and are ready to be shipped out
• Grey bins/labels: used to indicate storage areas
• Blue bins/abels: used to indicate machines and equipment areas
• Yellow bins/labels: used for inventory

Color coding is a way to failsafe/mistake proof, hence impacting in a favorable way overall quality. Additionally, besides any cycle time reduction and/or waste elimination the color coding tool will bring to the organization, it is important to acknowledge that an organized workspace perk up employees productivity and whay not to say, employees morale.

In summary, color coding method is so effective as it communicates a message in less time than any other method (standard procedures, training slides, ...). A color visual tool is easy to implement and can be used almost any place in the workplace baing one of the least expensive ways to organize a company and reduce overhead costs.

Have you implemented color coded visual tools in your workspace? Share your experiences and before/after results.

Should you need assisstance identifying the rigth visual tools for an overall improvement in your company contact us.

5S Overview -- A simple tool with significant impact

What is 5S? A brief definition is it is a practical 5 step process to help organize and maintain organization throughout your workspace. However, 5S is much more than housekeeping; it is effectively a tool to organize and visualize the workplace.  The 5 steps are:  

Step 1: Seiri (Sort)
• Clearing and classifying through everything in the work area. Separate the clutter from the needed items.
Step 2: Seiton (Straighten)
• Set in order the items in a way to improve efficiencies, safety and quality. Designate a specific correct location for the items.
Step 3: Seiso (Shine)
• Clean everything and keep it that way. Define ways to keep clean areas.
Step 4: Seiketsu (Standardize)
• Develop the routines and standard practices for regularly and systematically repeating the first three S’s. Generally this is accomplished through the use of visual management and standard operating procedures.
5: Shitsuke (Sustain)
• Engage your organization to ensure that 5S becomes part of the culture of your workplace.

The 5S is a simple easy to adopt lean tool with proven results including: defines standards for consistent results, reduction in required floor space, and reduction in iventory.
Although 5S requires to develop a discipline and deploy training to the organization on the tool details, it is true it is an initiative of minimal investment other than time. Have you implemented 5S your organization? What was your biggest challenge? What was your greatest achievement as a result of the 5S implementation?

Should you need further details on the 5S tool implementation (worksheets, training) contact us at qualityintegration@gmail.com.