CLL Visual Management & 5S Methodology Flashcards

What is the primary purpose of visual management in a lean workplace?

Answer: To make the status of operations, standards, and problems immediately visible to anyone

Visual management exposes abnormalities instantly so that anyone on the floor can see whether conditions are normal or require action without asking.

Which of the five 5S steps focuses on establishing rules and schedules to maintain the first three S conditions?

Answer: Standardize (Seiketsu)

Standardize creates the norms, checklists, and visual controls that sustain Sort, Set in Order, and Shine activities consistently over time.

In 5S, what is the correct action taken with items tagged during the 'Sort' step that are deemed unnecessary?

Answer: Move tagged items to a red-tag area for evaluation and disposition decision

Red-tag areas hold items pending a structured decision process — kept, relocated, or discarded — preventing arbitrary disposal of potentially useful items.

What does an andon system provide in a lean visual management context?

Answer: A real-time signal that alerts the team to a production problem requiring immediate response

Andon signals — lights, boards, or alerts — notify team leaders and support staff instantly when a worker detects an abnormality, enabling rapid response.

Which visual tool defines the acceptable range of a process parameter directly at the point of use?

Answer: Color-coded gauge with green, yellow, and red zones on the machine

Color-coded gauges at the point of use let operators instantly see whether a parameter is within spec (green), borderline (yellow), or out of range (red).

How does shadow boarding (shadow boards) support the 5S 'Set in Order' step?

Answer: It uses silhouette outlines so missing or misplaced tools are immediately obvious

Shadow boards show the exact shape and location for each tool; an empty shadow signals immediately that a tool is missing or not returned.