By Fidel
During my first visit to a factory located in a US/Mexico border town, my initial impression was positive: “It’s better organized than imagined. It sounds like there’s a good operating rhythm. And it smells like what a chemical processing factory should.”
Early in my career, a Manufacturing VP taught me that when visiting a factory, you should first do a “walk about.” Good housekeeping practices meant there was a fighting chance the financials would also be decent. But never was there a situation when a factory with poor housekeeping also had good numbers.
In this case, all signs were pointing towards good metrics for the maquiladora.
Then I sat in on the management team’s daily staff meeting—where all their metrics were “in the red.”
What went wrong?
It turned out the metrics were not presented in simple terms and goals such that staff could answer one basic question: “Did we win today?”
What Is Visual Management?
Visual Management (VM) is a graphical way to communicate plant performance, standards, warnings, and expectations—without requiring a lot of explanation.
When done right, anyone walking through the facility should be able to understand:
- Are we on track or off track?
- What’s the standard we’re trying to meet?
- Where are the problems?
- Who is responsible for addressing them?
If your metrics require lengthy explanations or specialized knowledge to interpret, they’re not doing their job.
Components of a Strategic Visual Management Program
1. Facility-Wide Communication
Data must be widely and commonly shared. Typically, this is done through a facility-wide notice board or glass wall that shows:
- Color-coded graphs of weekly/monthly performance
- Customer feedback
- Team actions and improvement initiatives
- Suggestions from team members
This is a good start—but only a small piece of the system.
2. Expected Standards and Targets
It’s just as important to share the expected standard. For every metric, people should know:
- What is the target?
- How is it being addressed?
- What actions are underway to close gaps?
Without visible targets, red and green indicators lose meaning.
3. Operational Boards at Each Work Area
The VM system should include boards at each major operation showing daily metrics relevant for that area. These boards answer: “How did our team perform today?”
4. Task Templates and Priorities
Templates that indicate what tasks need to be completed—by when, by whom, and in what priority—help clearly communicate priorities so everyone acts in the same direction.
Without this clarity, the leadership team must take responsibility for all issues by constantly digging in to assist.
Tools for Highlighting Abnormalities
A good VM system should clearly highlight abnormalities—making problems visible before they become crises.
| Tool | What It Does | Example |
|---|---|---|
| Shadow Boards | Draw attention to missing tools as a passive warning | Outlined tool storage where gaps are immediately visible |
| Statistical Process Control (SPC) | Enables team members to recognize when a process is going out of control | Control charts showing when variation exceeds limits |
| Poka-Yoke | Mistake-proofing that prevents errors from occurring | Fixtures that only accept correctly oriented parts |
| Andon Systems | Visual/audible signals that alert teams to problems in real-time | Lights or displays that trigger when a line stops |
| Color Coding | Quick visual differentiation of status or category | Green/Yellow/Red indicators for on-track, at-risk, off-track |
These tools work below the surface, enabling continuous improvement without constant management intervention.
The “Did We Win Today?” Test
The simplest test for your visual management system: Can every team member answer “Did we win today?” within seconds of looking at the board?
If the answer requires:
- A manager to explain the metrics
- Specialized knowledge to interpret charts
- More than a few seconds of analysis
…then your visual management isn’t visual enough.
The goal is clarity at a glance—so everyone can act in the same direction.
Ready to Improve Your Visual Management?
If your metrics are “in the red” but your team can’t explain why—or what to do about it—your visual management system needs work.
Contact us to discuss how OpExecs can help you build a VM system that drives action and results.