Lean Visual Management 4.0 is an essential tool for improving operational efficiency in manufacturing plants, and facilitating decision-making based on clear, up-to-date data. Technological advances mean that modern factories can make good use of visual management to monitor and interpret key performance indicators in real time. How is the method defined? And how has it evolved with Industry 4.0, aka the fourth industrial revolution? This is what we’ll be covering in this article.
What is lean visual management 4.0?
Visual management is a way of visually representing the most important information for the company, and displaying it in a way that is clear and understandable to all team members.
On the production floor, visual management makes it possible to detect anomalies, and see at a glance whether the operators are taking action to resolve these problems. Displaying the relevant indicators provides overall visibility of the site, enabling you to steer industrial performance and manage the factory’s different activities more effectively.
An essential component of lean management, visual management is essential to the DMAIC method, kamishibai chart and PDCA method, among others. Before the advent of Industry 4.0, visual management tools relied on physical media such as whiteboards, bulletin boards or paper records. Excel files or project management software were used to collect and visualize data in some cases.
Who hasn’t used sharpies or post-its to enable teams to visually track project progress and share information? However, while traditional visual management tools are effective, they have their limitations, which can be overcome using new technologies.
From paper to interactive dashboards: progress through new technologies
The advent of Industry 4.0 has brought about a major transformation in the way visual management is used on the factory floor. Advanced digital technologies, such as the Internet of Things (IoT), sensors and data management software, now make it possible to collect, analyze and display information in real time. This opens up new opportunities for factories to improve their operational performance through more dynamic, interactive and connected visual management.
A huge amount of data is collected, then processed and displayed clearly and visually on interactive dashboards, tablets or even smartphones, making the information easily accessible by all concerned.
Data is presented intuitively, with graphs, charts, colors and visual alerts, making it easier for staff to:
- Track data and trends, with a visually attractive display that is easy to interpret.
- Detect gaps compared to targets, through colors and visual alerts.
- Communicate, discuss and collaborate within the team, which fosters transparency, commitment and empowerment, and promotes a culture of continuous improvement.
The 3 main benefits of lean visual management 4.0 on the factory floor
Lean Visual Management 4.0 has many benefits to offer production plants, improving their operational efficiency and data-driven decision-making. The key ones are:
Improved transparency, communication and teamwork
Lean Visual Management 4.0 promotes transparency by providing all team members with an overview of the factory’s performance. Staff can track progress in real time by visualizing key performance indicators (KPIs) such as quality and downtime. Communication is more fluid, facilitating collaboration and strengthening the team’s commitment to achieving shared goals.
Informed decision-making
With real-time data displayed thanks to Lean Visual Management 4.0, managers can make informed, evidence-based decisions. Interactive dashboards and visual indicators help to quickly identify any anomalies. Clear information facilitates analysis and detection of causes, and implementation of effective corrective measures.
Improved productivity and efficiency
Lean Visual Management 4.0 boosts productivity and efficiency by enabling teams to quickly identify areas that are in need of improvement. By visualizing plant performance data, operators can track their own results, identify opportunities for improvement and share best practices. This promotes individual and collective empowerment, motivating employees to work together to achieve objectives, and encouraging continuous process improvement.
Lean Visual Management 4.0 is an evolution of the lean method of displaying information, and has been made possible by technical advances such as IoT and improved data processing speeds. This has many advantages in a production environment, as it facilitates communication, aids decision-making, and contributes to improved productivity, for better industrial performance.
