Are shadow boards Strong Standards? Benefits and pitfalls. A nice board and disappointing behavior. What are the alternatives?

1. Standards ?
Yokoten
Shadowboards
are
Strong

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3. SHADOW BOARDS
• A Board
• On a Central place
• With Tools,
• Changeover tools (SMED board), or
• Cleaning devices (broom station)

4. BENEFITS of SHADOW BOARDS
• Tools are on one place (5S)
• Easy to find
• It looks neat and orderly
• There are no more tools than necessary
• Easy to see which tool is missing

5. Shadows

6. SORT
SET IN ORDER
SHINE
STANDARDIZE
SUSTAIN
No unnecessary items
A place for everything, everything in it’s place
The 5S’s
Shadowboards are
used in the 2nd S: Set
in Order
1
2
3 4
5

7. SHADOW BOARDS
A Shadow board is the standard:
The fixed place for tools

8. 1. Are easy to use
2. Work Intuitively
3. Give a reward (f.i. time saving or less effort)
4. Are made by the users
5. Make compliance (the 5th S – Sustain)
easier
STRONG STANDARDS

9. 6. Do not introduce more or other types of
waste
STRONG STANDARDS

10. TYPES OF WASTE*
DEFECTS
SEARCHING
REWORK
WAITING
UNUSED
TALENT
TRANSPORT
MOTION
INSPECTION
INVENTORY * what? More than 7?
OVERPROCESSING

11. TYPES OF WASTE
SEARCHING
TRANSPORT
MOTION
New types of waste due to
shadow boards
or

12. Because shadow boards hang in a
central location,
people need to walk more.
Picking up and bringing tools

13. The more frequently tools are used,
The more walking,
The less likely the tools
are to be returned

14. SPAGHETTI DIAGRAM
Shadow board
Spaghetti diagram showing
the walking route of
operators during a setup
Picking up and
taking tools from
the central placed
shadow board

15. ARE
SHADOW BOARDS
STRONG STANDARDS ?
Decide for yourself

16. People tend to take tools from the
shadow board,
But do not bring it back
(and keep it to themselves)

17. And besides:
When the shadow board has an empty
spot,
WHERE is the missing tool?

18. Where is the
screwdriver?
Who has it?
WHERE?

19. Shadow boards are easy to make
But
Hard to sustain
5th S SUSTAIN

20. • There are main tasks and side tasks
• People tend to forget side tasks that come
after main tasks
• Such as forgetting to put the fuel cap back on
the gas tank (side task) after filling up (main
task)
POST COMPLETION ERROR

21. • Shadow boards are fine
• But what works sometimes
better?
ARE THERE ALTERNATIVES?

22. Store tools where they are used.
Not in a central location

23. • Indeed, sometimes you need
several copies of the same tool
in different places
• Which is more inventory
SIDE EFFECT
INVENTORY

24. Make the shadow board
Movable
So you can grab it when needed
SEARCHING

25. • A shadowboard on wheels
• Give it a fixed place
ALTERNATIVES

26. Rather no tools,
Replace them with smart fastening
systems
(no tools needed)

27. No tools,
No shadow board
No compliance

28. EASY FASTENERS

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Bert Teeuwen
Uitgeverij Yokoten
Elke (internet-)boekhandel
Yokoten