Lean Six Sigma

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About

https://en.wikipedia.org/wiki/Lean_Six_Sigma (LSS)

DOWNTIME is an acronym in LSS representing 8 forms of waste. Defects. Overproduction. Waiting. Transportation. Non-used talent, Inventory. Motion. Extra processing.

Here are some useful icons [1]:

Leanicons.png

Kaizen (Continuous Improvement) vs Six Sigma

Kaizen Six Sigma
Continuous small improvements (everyday change) Structured, project-based defect and variation reduction
Everyone participates; frontline-driven Typically led by trained roles (Green/Black Belts) with executive sponsorship
Cultural mindset and habits; improvement as part of daily work Methodology with defined phases and deliverables (DMAIC/DMADV)
Fast experimentation; “try, learn, standardize” Data- and analysis-intensive; statistical tools common
Focus: flow, waste reduction, work standardization, ergonomics Focus: variation control, capability, defect reduction (DPMO, sigma level)
Measurement: simple operational metrics (lead time, WIP, rework, safety) Measurement: process capability, control charts, hypothesis tests, DOE
Best for: high-frequency opportunities, local process improvements Best for: chronic quality problems, complex cross-functional processes
Typical cadence: daily/weekly improvements; occasional Kaizen events Typical cadence: defined projects lasting weeks to months

5S Method for Clean Organization

Japanese English Operational meaning Audit checklist (yes/no or score 0–2 each)
Seiri Sort Remove unnecessary items from the workspace
  • Only necessary tools/materials are present at the point of use
  • Red-tag area exists and is used (items moved there within 24 hrs)
  • No expired, broken, or duplicate items occupying prime space
  • Work areas/aisles are free of stored items and clutter
  • Unused jigs/fixtures/materials are removed or stored in designated overflow
Seiton Set in Order Arrange needed items for efficient access
  • Every item has a clearly labeled “home” (location + label visible)
  • Items are stored by frequency of use (daily items closest, rarely used farther)
  • Shadow boards / outlines / bin labels match current contents
  • Point-of-use storage exists for consumables (fasteners, tape, blades, etc.)
  • No searching: common items can be retrieved in <30 seconds
Seiso Shine Clean and inspect the workspace
  • Floors, benches, and machines are clean (no buildup, chips, dust, spills)
  • Cleaning tools are available and stored at point of use
  • “Clean-to-inspect”: leaks, wear, looseness, or damage are easy to spot
  • Daily cleanup is performed at end of shift (documented or observable)
  • Abnormalities found during cleaning are tagged and reported
Seiketsu Standardize Establish procedures to maintain first 3 S’s
  • Standard work exists for cleanup, restock, and tool return (posted)
  • Visual standards exist (photos/diagrams) for “what good looks like”
  • Restock levels (min/max) are defined for consumables
  • Responsibilities are assigned (who, what, when) for each area
  • 5S audit schedule is posted and followed (weekly/monthly cadence)
Shitsuke Sustain Build discipline and habit to keep standards
  • Regular audits occur and scores are tracked over time
  • Issues found in audits have owners and due dates (closed-loop)
  • New people are trained on 5S standards during onboarding
  • Leaders do routine gemba walks and reinforce standards
  • Standards are improved when reality changes (no “stale” rules)

Visual Workshop and Organization Master List

Source - [2]

1. Visual Control Foundations

Workspace Zoning

  • Floor tape color-coded zones (materials staging, finished goods, scrap, WIP)
  • Defined walkways with safety yellow lines
  • “No-storage” red hash zones
  • Forklift travel lanes
  • Visitor safe zones

Tool Visibility

  • Shadow boards (outlined tool shapes)
  • Tool ID numbers engraved or labeled
  • Dedicated location for every tool
  • Tool checkout board (shared tools)
  • Missing tool indicator flags

Labeling System

  • Standard label format (font, size, color)
  • Label every shelf, drawer, bin, cabinet
  • QR codes for procedures or manuals
  • Laminated large-format zone labels
  • Material category color coding

2. 5S Infrastructure

Sort Systems

  • Red tag area
  • Red tag log sheet
  • Quarterly purge schedule
  • Obsolete material quarantine zone

Set in Order

  • Fast-mover tools closest to point of use
  • Min/max bins with visual fill lines
  • Consumable Kanban cards
  • Drawer dividers with silhouettes
  • Standard fastener racks with size labeling

Shine

  • Cleaning stations at each zone
  • Color-coded cleaning tools by area
  • Daily 5-minute cleanup standard
  • Equipment wipe-down checklist
  • “Clean-to-inspect” lighting

Standardize

  • Photo standard boards (“what good looks like”)
  • Area ownership board
  • Posted restock standards
  • Visual SOP sheets at workstation

Sustain

  • 5S audit board with scoring
  • Monthly audit calendar
  • Improvement idea board
  • Before/after photo board

3. Flow and Production Visibility

Workflow Visualization

  • Value stream map posted
  • Production flow arrows on floor
  • Job travelers clipped to work
  • Build status board (To Do / Doing / Done)
  • Daily production target board

Bottleneck Visibility

  • WIP limit signs
  • Queue size max lines marked
  • “Blocked” red tag cards
  • Downtime reason board

Scheduling and Planning

  • Weekly lookahead board
  • Takt time clock display
  • Visual daily huddle board
  • Material pull board

4. Safety Visual Systems

  • PPE required signage by zone
  • Machine hazard labeling
  • Emergency exits clearly marked
  • Fire extinguisher locations outlined
  • First aid station marked with stocked indicator
  • Lockout/tagout station with tags visible
  • Safety cross board (days since incident)

5. Quality at the Source

  • First-piece approval board
  • Sample “gold standard” parts displayed
  • Inspection checkpoints marked
  • Error-proofing (poka-yoke) fixtures
  • Go/No-Go gauges visibly mounted
  • Defect board with root cause tracking
  • Calibration due-date tags on tools

6. Material and Inventory Control

  • FIFO lanes marked
  • Date stickers on inventory
  • Raw vs finished goods zones separated
  • Scrap bin clearly marked and isolated
  • Supplier label standard
  • Material staging racks at point of use
  • Reorder point visual cards

7. Equipment Management

  • Preventive maintenance board
  • Machine status lights (green/yellow/red)
  • Tool life tracker (drill bits, blades)
  • Spare parts shadow board
  • Maintenance log posted at machine

8. Communication and Leadership

  • Gemba walk board
  • Improvement tracking board
  • Suggestion box (physical or digital)
  • KPI wall (Safety / Quality / Delivery / Cost / Morale)
  • Escalation ladder posted (who to call, in what order, with response times)
  • Leadership standard work posted

9. Advanced Visual Systems

  • Andon lights
  • Digital dashboard screens
  • RFID tool tracking for check-in/out and location-at-last-scan
  • Barcode material tracking
  • Visual torque verification marks
  • Laser-projected layout guides
  • Smart Kanban bins
  • Electronic traveler system

10. Cultural Visual Reinforcement

  • “Before and After” improvement wall
  • Skill matrix board
  • Training progress board
  • Certification badges
  • Core values display
  • Improvement wins highlight board

Implementation Sequencing

  1. 5S foundation
  2. Workflow visibility
  3. Quality and safety reinforcement
  4. Material control systems
  5. Advanced automation and digital visual controls

Design Rule

Every visual system should answer at least one question immediately:

  • What is supposed to happen?
  • What is happening now?
  • Is there a gap?
  • Who owns the gap?
  • What is the next action?

Gemba Walk

A Gemba Walk is a structured leadership practice where managers go to the actual workplace (shop floor, job site, lab, office) to:

  • Observe the process directly
  • Ask questions
  • Understand problems firsthand
  • Support continuous improvement
Section What to observe / ask Evidence to capture Rating (0–2)
Walk setup
  • Purpose/theme for today is clear (Safety / Quality / Flow / 5S / Training)
  • Route and timebox defined (e.g., 20–30 min)
  • Go to point of use (where value is created), not the office
  • Theme stated
  • Areas visited
  • Time started/ended
 0–2
Safety
  • Any immediate hazards (trip, pinch, electrical, overhead load, PPE gaps)?
  • Are guards, lockout/tagout, and signage in place where needed?
  • Ask: “What safety concern are you most worried about today?”
  • Hazard list + location
  • Photos of hazards (if allowed)
  • Owner + due date for fixes
 0–2
Quality at the source
  • Is the standard for “good” visible at the workstation (spec, jig, template)?
  • Is first-piece/first-article verification happening?
  • Are defects detected immediately, or discovered later?
  • Ask: “What causes rework here?”
  • Defect/rework examples
  • Standard references used (doc/photo/jig)
  • Containment actions
 0–2
Flow and bottlenecks
  • Where is work waiting (queues, WIP piles, stalled tasks)?
  • Are downstream steps starved or blocked?
  • Ask: “What is slowing this step down right now?”
  • Bottleneck step identified
  • WIP counts (rough)
  • Wait reasons
 0–2
Standard work adherence
  • Is there a known best method? Is it being followed?
  • Are deviations visible and explained?
  • Ask: “What part of the standard doesn’t match reality?”
  • Standard work posted (Y/N)
  • Deviation notes
  • Improvement opportunities
 0–2
5S and visual management
  • Sort: clutter/red-tag items present?
  • Set in order: tools labeled and in their homes?
  • Shine: clean-to-inspect condition?
  • Standards posted and current?
  • Ask: “Do you spend time searching for tools/materials?”
  • 5S gaps by S
  • Photos of before/after (if allowed)
  • Time-to-find estimate
 0–2
Materials and logistics
  • Are materials staged at point of use in the right quantity?
  • Are there stockouts or overstock?
  • Are pull signals (Kanban/min-max) in place?
  • Ask: “What materials do you run out of most often?”
  • Stockout list
  • Overstock list
  • Reorder triggers (Y/N)
 0–2
Equipment and uptime
  • Any downtime, jams, tool failures, or workaround behavior?
  • Is preventive maintenance visible and current?
  • Ask: “What equipment causes the most interruptions?”
  • Downtime causes
  • Maintenance tags/logs
  • Needed spares/tools
 0–2
People, training, and engagement
  • Are roles clear? Any confusion on handoffs?
  • Training needs visible (new task, new tool, new standard)?
  • Ask: “If you could change one thing today, what would it be?”
  • Training gaps
  • Suggestions captured
  • Blockers requiring leadership action
 0–2
Problem solving and follow-up
  • Are issues tracked with owners and due dates?
  • Are yesterday’s actions closed or progressing?
  • Ask: “Which open issue is most painful right now?”
  • Action log entries (owner, due date)
  • Escalations needed
  • Next check-in date
 0–2
Closeout
  • Summarize key observations to the team (no blame)
  • Confirm next steps, owners, dates
  • Thank the operators; confirm how feedback will be used
  • Top 3 issues
  • Top 3 quick wins
  • Commitments made
 0–2

Scoring suggestion: 0 = not in place / concerning; 1 = partially in place; 2 = consistently in place. Capture 3–5 actionable items per walk and review closure on the next walk.

Visual Workshop Implementation Template

Visual Workshop item Implementation procedure (minimum viable steps) Effort (labor) Material cost (USD, typical)
Floor tape color-coded zones (staging, WIP, finished, scrap) 1) Sketch current layout and define zones
2) Assign color standard and publish legend
3) Sweep/degrease floors
4) Tape/paint boundaries and zone labels
5) Train crew on “what belongs where” 		4–12 hrs $300–$1,200 (tape/paint, labels)
Defined walkways + “no-storage” red hash zones 1) Identify primary travel routes and pinch points
2) Mark walkways (yellow) and no-storage areas (red hash)
3) Post enforcement rule (“nothing stored here”)
4) Audit daily for first 2 weeks 		2–8 hrs $100–$600
Forklift lanes and pedestrian separation 1) Map forklift routes and crossings
2) Mark lanes, crossings, and stop points
3) Add mirrors/signage at blind corners
4) Brief all personnel; enforce right-of-way rule 		4–10 hrs $200–$1,500 (tape, signs, mirrors, bollards optional)
Visitor safe zones 1) Define visitor paths and viewing areas
2) Mark “visitor only” zones and barriers
3) Post PPE rules and escort requirement 		1–3 hrs $50–$300
Shadow boards (tool outlines) at point of use 1) Inventory tools per station
2) Mount board and hooks
3) Place tools and trace outlines (paint/vinyl)
4) Label homes; add “missing tool” indicator
5) Standard: tools returned end-of-task 		2–6 hrs per board $80–$250 per board
Tool ID numbers (engraved/labeled) + master tool list 1) Assign unique IDs (format: TOOL-###)
2) Label/engrave tools
3) Create master list (ID, type, home, owner/crib)
4) Update process for new tools and retirements 		4–12 hrs (initial) $50–$400 (labels/engraver consumables)
Dedicated “home” for every tool (drawers, hooks, bins) 1) Define storage topology per station
2) Add dividers/foam silhouettes where needed
3) Label each location (same naming convention)
4) Remove duplicates/unused tools to overflow storage 		6–20 hrs (shop-wide) $150–$1,500 (dividers/foam/containers)
Tool checkout board (shared tools) 1) Define which tools require checkout
2) Create physical board (magnet tags/cards) or digital log
3) Rule: no tool leaves crib without checkout
4) Weekly review of chronic holdouts 		3–8 hrs $50–$300
Missing tool indicator flags (visual abnormality) 1) Add a flag/placeholder for each tool home
2) Flag visible when tool absent
3) End-of-day “all flags cleared” check 		1–3 hrs per station $10–$80 per station
Labeling standard (font, size, color, format) 1) Define label conventions (Area–Rack–Shelf–Bin)
2) Choose printer + label stock
3) Publish style sheet and examples
4) Enforce: no unlabeled storage 		2–6 hrs $200–$700 (printer + labels)
Label every shelf/drawer/bin/cabinet 1) Walk the shop and inventory storage points
2) Print/apply labels systematically by zone
3) Add QR codes only where SOPs exist
4) Weekly “label drift” correction 		6–24 hrs (shop-wide) $50–$400 (labels)
QR codes for procedures/manuals (optional) 1) Create SOP pages (PDF/wiki) with stable URLs
2) Generate QR labels and place at point-of-use
3) Test with phones; fix broken links
4) Update SOP revision control 		4–16 hrs $20–$200
Material category color coding (labels/bins) 1) Define categories (fasteners, electrical, plumbing, adhesives, etc.)
2) Assign colors and publish legend
3) Apply colored tape/labels consistently
4) Audit mis-sorts weekly 		4–12 hrs $50–$400
Red tag area (Sort) + quarantine zone 1) Allocate a clearly marked red-tag zone
2) Create red-tag cards + log sheet
3) Run a 2-hour “sort blitz” per area
4) Set disposal/relocation rule at 30 days 		4–12 hrs (initial) $25–$150
Quarterly purge schedule (Sort sustainment) 1) Put purge weeks on calendar (quarterly)
2) Assign area owners to execute
3) Record volume removed and reclaimed space
4) Adjust min/max to prevent re-accumulation 		1–2 hrs/month ongoing $0–$50
Fast-mover tools/materials closest to point of use 1) Identify top 20 frequently used items per station
2) Relocate to point-of-use storage
3) Push slow movers to secondary storage
4) Validate: retrieval <30 seconds 		4–10 hrs $0–$400 (bins/racks if needed)
Min/max bins with fill lines 1) Select consumables to control (top 20–50)
2) Set min/max levels based on usage cadence
3) Add fill lines and reorder trigger cards
4) Assign restock owner + daily check 		6–16 hrs $100–$600
Consumable Kanban cards 1) Create Kanban cards (item, part #, reorder qty, supplier)
2) Place at min level in bin
3) Define “card goes to order box” process
4) Weekly audit for stockouts 		4–12 hrs $25–$200
Drawer dividers / foam cutouts for tools 1) Select drawers with chronic mess/searching
2) Design layout; cut foam or insert dividers
3) Label each cavity/slot
4) Enforce return-to-home standard 		1–4 hrs per drawer $30–$150 per drawer
Standard fastener racks with size labeling 1) Standardize fastener SKUs (reduce variety)
2) Install rack/bins and label each size
3) Add min/max and reorder triggers
4) Remove mixed “coffee can” storage 		6–16 hrs $200–$1,500
Cleaning stations (brooms/rags/chemicals) by zone 1) Define cleaning tool set per zone
2) Mount racks and label homes
3) Post “end-of-shift 5 minutes” standard
4) Assign zone owner for compliance 		2–6 hrs per station $150–$500 per station
Color-coded cleaning tools by area (cross-contamination control) 1) Assign color per area (bath, food, finish, general)
2) Purchase matching tools
3) Label station and enforce “no mixing” 		1–2 hrs $50–$250
Equipment wipe-down checklist (clean-to-inspect) 1) Identify machines requiring daily/weekly wipe-down
2) Create laminated checklist at machine
3) Add sign-off and escalation for abnormalities 		2–8 hrs $10–$80
“Clean-to-inspect” lighting improvements 1) Identify inspection/precision work areas
2) Add task lighting and glare control
3) Validate visibility for defects/leaks 		2–6 hrs $50–$600 per area
Photo standard boards (“what good looks like”) 1) Photograph ideal setups (before/after, tool wall, staging)
2) Print/laminate and post at station
3) Include 3–5 “do not” photos for clarity 		4–12 hrs $50–$300
Area ownership board 1) Divide shop into named zones
2) Assign owners (name + backup)
3) Post responsibilities (5S, restock, safety checks)
4) Review weekly 		1–3 hrs $20–$150
Visual SOP sheets at workstation 1) Identify repetitive tasks (top 10)
2) Write 1-page SOP with photos + critical dims
3) Laminate and mount at point-of-use
4) Revision control (date/version) 		1–4 hrs per SOP $5–$20 per SOP
5S audit board with scoring 1) Define audit checklist and scoring (0–2)
2) Post board by zones
3) Schedule weekly audits
4) Track trends and close actions 		3–8 hrs setup; 1–2 hrs/week $50–$250
Monthly audit calendar 1) Publish audit schedule (who audits what, when)
2) Post on wall near huddle board
3) Enforce: missed audits are visible 		1 hr $0–$20
Improvement idea board + suggestion box 1) Create simple capture format (problem, idea, owner, date)
2) Place physical box or QR intake form
3) Review weekly; move ideas to action log 		2–6 hrs setup; 30–60 min/week $20–$200
Before/after photo wall 1) Take baseline photos of key areas
2) Post improvements with date + owner + result metric
3) Refresh monthly to reinforce culture 		2–6 hrs setup; ongoing small $20–$150
Value Stream Map (VSM) posted 1) Map current process steps and delays
2) Identify bottlenecks and WIP points
3) Post current-state map and target-state actions
4) Review monthly 		8–20 hrs $0–$200 (printing/board)
Production flow arrows on floor 1) Define intended material/workflow direction
2) Place arrows and station labels on floor
3) Remove conflicting paths; enforce staging discipline 		2–6 hrs $50–$300
Job travelers clipped to work 1) Define traveler template (job, spec, steps, QC points)
2) Print and attach to carts/modules
3) Require sign-off at checkpoints 		4–12 hrs setup $20–$200 (clipboards, sleeves)
Build status board (To Do / Doing / Done) 1) Install board
2) Define columns and WIP limits
3) Standardize card format
4) Daily 10-minute update in huddle 		2–6 hrs setup; 10 min/day $100–$600
Daily production target board 1) Define daily targets by station
2) Post planned vs actual
3) Review gaps and assign countermeasures 		2–4 hrs setup; 10 min/day $20–$200
WIP limit signs + queue max lines marked 1) Set WIP caps per station (based on capacity)
2) Mark max queue footprints on floor
3) Enforce “stop starting, start finishing” 		2–6 hrs $20–$200
“Blocked” red tag cards (work stoppage visibility) 1) Create blocked cards (reason, owner, timestamp)
2) Rule: any blocked work gets a card
3) Review in huddle; escalate if overdue 		1–3 hrs $10–$50
Downtime reason board (by machine/area) 1) Define downtime codes and threshold (e.g., >10 min)
2) Post board near equipment
3) Require entries; review weekly trends 		2–6 hrs setup; 15 min/week $20–$150
Weekly lookahead board 1) List next 1–2 weeks of work by zone
2) Identify constraints (materials, inspections, labor)
3) Update weekly with owners 		2–6 hrs setup; 30–60 min/week $20–$250
Visual daily huddle board 1) Create huddle agenda (Safety/Quality/Delivery/Issues)
2) Post key metrics and today’s plan
3) Run 10-minute huddle at fixed time 		2–6 hrs setup; 10 min/day $20–$250
Material pull board (kitting/staging) 1) Define kit lists per module/task
2) Create pull cards per kit
3) Staging area labeled by kit
4) Validate kit completeness before release 		6–20 hrs $50–$600
PPE required signage by zone 1) Define PPE rules per zone
2) Post signs at entries
3) Enforce in daily huddle and gemba 		1–3 hrs $50–$300
Machine hazard labeling 1) Label pinch points, hot surfaces, moving parts
2) Add lockout points labeling
3) Verify labels survive cleaning/abuse 		2–8 hrs $50–$400
Emergency exits clearly marked 1) Verify egress paths are unobstructed
2) Install/refresh signage and floor markings
3) Monthly walk-through audit 		1–4 hrs $50–$300
Fire extinguisher locations outlined + signage 1) Confirm correct extinguisher types/placement
2) Outline footprint and add sign above
3) Add inspection tag discipline 		30–60 min each $10–$50 each
First aid station marked with stocked indicator 1) Mount first aid cabinet at known location
2) Mark with signage and floor outline
3) Add simple “stock OK / stock low” indicator
4) Monthly restock owner 		1–3 hrs $50–$300
Lockout/tagout (LOTO) station with tags visible 1) Install LOTO station near equipment cluster
2) Label lock points on machines
3) Train crew; enforce LOTO procedure 		4–12 hrs $100–$800
Safety cross board (days since incident / near-miss) 1) Create board with daily boxes
2) Define what counts as near-miss
3) Update daily; review in huddle 		1–3 hrs setup $20–$150
First-piece approval board 1) Define first-piece criteria and measuring tools
2) Create sign-off checklist
3) Require approval before batch/run proceeds 		4–10 hrs $20–$200
“Gold standard” sample parts displayed 1) Select best-known-good samples
2) Mount in labeled display case near station
3) Replace when spec changes 		2–6 hrs $20–$200
Inspection checkpoints marked 1) Identify critical-to-quality steps
2) Mark checkpoint location on flow board and physical area
3) Add go/no-go gauges or checklist 		4–12 hrs $50–$800 (depends on gauges)
Error-proofing fixtures (poka-yoke) 1) Identify top 3 recurring errors
2) Design simple physical constraint/jig
3) Pilot and validate defect reduction
4) Standardize across stations 		8–40 hrs (depends) $50–$2,000 (materials + fabrication)
Go/No-Go gauges mounted visibly 1) Identify critical dimensions
2) Procure/make go/no-go gauges
3) Mount at point-of-use with label and calibration date 		4–16 hrs $50–$1,500
Defect board with root cause tracking 1) Create board: defect, frequency, cause, countermeasure, owner, due date
2) Log defects daily
3) Weekly review; close actions 		3–8 hrs setup; 30–60 min/week $20–$200
Calibration due-date tags on tools 1) Identify tools requiring calibration (torque, meters, levels)
2) Add dated calibration labels
3) Create re-cal schedule and owner 		2–6 hrs $20–$100
FIFO lanes marked + date stickers 1) Mark FIFO lanes for inbound/outbound
2) Add “oldest first” signage
3) Apply date stickers on receipt
4) Audit weekly for FIFO violations 		4–10 hrs $50–$300
Raw vs finished goods zones separated 1) Define clear physical separation
2) Label zones and enforce no-mixing
3) Add simple inbound/outbound rules 		2–8 hrs $50–$400
Scrap bin clearly marked and isolated 1) Place scrap bins at logical points
2) Label “scrap only” and outline footprint
3) Add rule: scrap never stored in WIP lanes 		1–3 hrs $20–$200
Supplier label standard 1) Define receiving label format (date, vendor, lot, PO, location)
2) Print labels at receiving desk
3) Enforce: no unlabeled stock enters racks 		4–12 hrs setup $50–$400
Material staging racks at point of use 1) Identify repeated staging needs per station
2) Procure/assemble racks/carts
3) Label rack positions and max WIP
4) Train: staging equals readiness 		6–20 hrs $200–$2,000
Reorder point visual cards 1) Identify reorder items and lead times
2) Create reorder cards with min qty and supplier info
3) Place at reorder point in bin
4) Weekly verify stockouts 		3–10 hrs $20–$200
Preventive maintenance board 1) List assets and PM intervals
2) Post board with due dates and owners
3) Record completion and issues found
4) Review weekly 		6–16 hrs setup; 1 hr/week $50–$400
Machine status lights (green/yellow/red) 1) Select machines where downtime is costly
2) Install stack lights and button inputs
3) Define response rules per color
4) Train and enforce 		4–12 hrs per machine $200–$1,500 per machine
Tool life tracker (bits/blades/consumables) 1) Define wear-life rules per tool type
2) Create tracker (board or log) at station
3) Standard: replace before failure when threshold hit 		2–6 hrs setup $0–$150
Spare parts shadow board 1) Identify top failure parts
2) Mount labeled storage for spares
3) Set min/max and reorder trigger 		4–10 hrs $50–$500
Maintenance log posted at machine 1) Mount log holder at each machine
2) Record downtime, fixes, recurring faults
3) Review monthly to drive PM improvements 		1–2 hrs per machine $5–$30 per machine
Gemba walk board 1) Post schedule + checklist + action log
2) Run regular gemba cadence
3) Track closure rate and repeat issues 		2–6 hrs setup; 1–3 hrs/week $20–$200
Improvement tracking board (action log) 1) Create board: issue, countermeasure, owner, due date, status
2) Review weekly; close items visibly
3) Archive completed improvements monthly 		2–6 hrs setup; 30–60 min/week $20–$200
KPI wall (SQDCM: Safety/Quality/Delivery/Cost/Morale) 1) Choose 4–6 metrics with clear definitions
2) Post baseline and targets
3) Update weekly; discuss in huddle 		6–16 hrs setup; 30 min/week $50–$800
Escalation ladder posted 1) Define escalation triggers (downtime, safety, quality)
2) Define levels (Lead → Manager → Exec) with response times
3) Post laminated chart at key points
4) Drill the process 		3–8 hrs $10–$100
Leadership standard work posted 1) Define leader daily/weekly routines (gemba, audits, reviews)
2) Post checklist and time windows
3) Track adherence and adjust 		4–12 hrs $20–$150
Andon lights (call-for-help system) 1) Install call button + light per station
2) Define response SLA and escalation
3) Log and analyze calls weekly 		6–16 hrs per line $300–$2,500 per station/line
Digital dashboard screens (optional) 1) Define what must be live (targets, WIP, alerts)
2) Mount displays and connect to data source
3) Assign owner for uptime and correctness 		8–30 hrs $300–$3,000+ (screens + compute)
RFID tool tracking (check-in/out, portal events) 1) Choose UHF passive tags and tag placement standard
2) Install portal reader at tool crib/exits
3) Configure software rules (authorized checkout vs alarm)
4) Add handheld reader for audits and recovery searches 		16–60 hrs (depends on scale) $3,000–$25,000 (tags + readers + setup)
Barcode material tracking (optional) 1) Standardize barcodes on received goods and internal kits
2) Add scanners at receiving and kitting
3) Integrate with simple inventory log 		8–30 hrs $200–$2,000
Visual torque verification marks 1) Define which fasteners require torque verification
2) Use paint pen witness marks after torque
3) Train inspectors to spot missing marks 		1–4 hrs setup $10–$100
Laser-projected layout guides (optional) 1) Identify repeated layout tasks (stud lines, cut lines, drill patterns)
2) Select projection system and mount rigidly
3) Calibrate and lock settings
4) SOP for calibration checks 		20–80 hrs $1,000–$20,000+
Smart Kanban bins (optional) 1) Select high-usage consumables
2) Install sensors or e-kanban triggers
3) Configure reorder notifications
4) Validate against actual consumption 		10–40 hrs $500–$10,000+
Electronic traveler system (optional) 1) Define traveler data model (steps, QC, sign-offs)
2) Choose device/workstation strategy (tablets/kiosks)
3) Pilot one line and iterate
4) Roll out with training 		40–200 hrs $1,000–$30,000+ (devices + software)
Skill matrix board 1) List roles/skills by station
2) Define rating scale (0–3) and evidence
3) Populate matrix and identify gaps
4) Update monthly/quarterly 		4–12 hrs setup; ongoing small $20–$200
Training progress board 1) Define training modules and checkoffs
2) Post per-person progress
3) Update weekly; tie to assignments 		2–6 hrs setup $20–$150
Certification badges (role qualification visibility) 1) Define cert criteria per role/tool (e.g., forklift, electrical)
2) Issue visible badges/stickers
3) Enforce: only certified persons run restricted operations 		4–12 hrs $20–$300
Core values display + “wins” highlight board 1) Select 3–5 operating principles and behaviors
2) Post in high-traffic area
3) Add weekly “wins” with concrete examples and metrics 		2–6 hrs setup $20–$200

Core Visual Workshop Costs: 5S + Flow + Safety + Boards

Scope (Included Systems)

  • Floor zoning
  • Shadow boards
  • Labeling system
  • Min/Max + Kanban (consumables control)
  • Cleaning stations
  • FIFO lanes
  • WIP limits
  • Status boards (work tracking)
  • Safety visuals
  • Audit boards (5S + safety + quality)
  • Escalation ladder (who to call / when)
  • KPI wall (SQDCM or similar)
  • Skill matrix (training + qualification visibility)
  • Defect board (quality at the source)
  • PM board (preventive maintenance visibility)

Estimated Material Cost

  • $4,000 – $12,000 (typical)

Cost Coverage (Typical Spend Categories)

  • Tape/paint (floor lines, zone markings, arrows)
  • Label printer + supplies (labels, label stock, laminating)
  • Boards (whiteboards, magnetic boards, bulletin boards)
  • Bins/racks (point-of-use storage, staging racks)
  • Dividers/foam (drawer organization, tool shadowing)
  • Signage (PPE, hazards, exits, instructions)
  • Lighting upgrades (basic task lighting where needed)
  • Basic maintenance tools (PM consumables, tags, holders)

Labor Effort

  • 200–400 internal hours over 4–8 weeks (typical)

Baseline Standard

This is the baseline for a serious professional shop:

  • Clear zones, labeled storage, and point-of-use organization
  • Visible workflow status and WIP control
  • Visible safety and quality standards at the workstation
  • Regular audits with ownership and follow-up
  • Metrics and escalation pathways posted and used

40-Hour Visual Workshop Sprint Plan

Objective

Establish a disciplined Core Visual Foundation in 40 hours (5 days × 8 hours):

  • Defined zones and flow
  • Zero tool searching at critical stations
  • Controlled consumables
  • Visible work status
  • Clear escalation pathway
  • Basic safety visibility
  • Audit + accountability structure

No digital systems. No overengineering.

Day 1 (8 Hours) – Define and Mark Structure

1. Map Zones (2 hrs)

  • Walk entire shop
  • Define: Raw, WIP, Finished, Scrap, Tool Crib, Staging
  • Sketch layout
  • Assign color standard

2. Floor Marking (4 hrs)

  • Tape/paint zone boundaries
  • Mark walkways
  • Mark no-storage zones
  • Mark FIFO lanes

3. Post Zone Legend (1 hr)

  • Print large color legend
  • Mount at entry and near huddle board

4. End-of-Day Walkthrough (1 hr)

  • Remove violations
  • Relocate misplaced materials

Outcome: Chaos now has borders.

Day 2 (8 Hours) – Eliminate Tool Searching

1. Identify Top 2 Pain Stations (1 hr)

  • Where is search time highest?

2. Install Shadow Boards (4 hrs)

  • Mount boards
  • Outline tools
  • Label homes
  • Remove duplicates

3. Fix Worst Drawers (2 hrs)

  • Add dividers or foam
  • Eliminate mixed bins

4. Tool ID + Home Rule (1 hr)

  • Label tools
  • Establish rule: tool leaves = tool returns

Outcome: Immediate search time reduction.

Day 3 (8 Hours) – Consumables & Material Control

1. Select Top 20 Consumables (1 hr)

  • Fasteners, blades, adhesives, etc.

2. Install Min/Max System (3 hrs)

  • Add fill lines
  • Install Kanban cards
  • Assign reorder owner

3. Clean & Set-in-Order Blitz (3 hrs)

  • Remove dead inventory
  • Organize by frequency of use
  • Eliminate mixed scrap

4. Define Scrap & Rework Area (1 hr)

  • Clearly mark
  • No mixing with WIP

Outcome: Reduced stockouts and clutter.

Day 4 (8 Hours) – Flow & Visibility

1. Install Status Board (2 hrs)

Columns:

  • To Do
  • Doing
  • Done
  • Blocked

2. Define WIP Limits (1 hr)

  • Mark max queue footprint per station

3. Create Daily Huddle Board (2 hrs)

Sections:

  • Safety
  • Quality
  • Delivery
  • Issues

4. Install Escalation Ladder (1 hr)

  • Define triggers
  • Define escalation tiers
  • Post chart visibly

5. First-Piece Quality Standard (2 hrs)

  • Define critical QC check
  • Post checklist at station

Outcome: Work becomes visible.

Day 5 (8 Hours) – Sustain & Control

1. Install 5S Audit Board (2 hrs)

  • Define scoring (0–2 scale)
  • Assign zone owners
  • Post audit cadence

2. Install KPI Wall (2 hrs)

Basic metrics:

  • Safety
  • Throughput
  • Defects
  • On-time completion

3. Install PM Board (2 hrs)

  • List machines
  • Add due dates
  • Assign owner

4. Safety Visual Sweep (1 hr)

  • PPE signage
  • Fire extinguisher marking
  • Exit visibility

5. Final Walkthrough + Rule Setting (1 hr)

Establish 3 hard rules:

  1. Nothing stored outside zones
  2. Tools return to home
  3. WIP limits enforced

Outcome: Accountability structure in place.

Cost Estimate

Materials

  • $2,000 – $6,000 typical

Labor

  • 40 internal hours

Measurable Outcomes After One Week

  • 30–60% reduction in tool search time
  • Fewer stockouts
  • Clear bottlenecks visible
  • Reduced clutter
  • Faster daily huddles
  • Visible ownership of areas

Sustainment Rule

After completion:

  • Schedule 1-hour weekly sustainment block
  • Run weekly audits for 4 consecutive weeks
  • Do not add complexity until discipline stabilizes

Discipline first. Systems later.

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