Module 8 · Lesson 9 of 29

Principle 7: visual control exposes abnormality

Learning objectives

Explain the purpose of principle 7: visual control exposes abnormality in garment operations.
Describe when and how to apply principle 7: visual control exposes abnormality on the shop floor.
Identify common mistakes and how to avoid them.

Simple visuals let anyone distinguish normal from abnormal without searching through reports.

Place at gemba, show current condition/owner/response, design for accessibility. Avoid red status with no escalation capacity.

Status lanes, limit marks, Andon, hourly boards and tool locations trigger defined action.

Pick one answer per question. Explanations appear after you submit.

1. Which statement best captures the core idea of Principle 7: visual control exposes abnormality?
- Simple visuals let anyone distinguish normal from abnormal without searching through reports.
- It is a purely financial control unrelated to shop-floor work.
- It replaces the need for standardized work and training.
- It applies only to fully automated factories.
2. A common mistake when applying principle 7: visual control exposes abnormality is to:
- Avoid red status with no escalation capacity
- Involve operators and validate with data.
- Link the tool to the observed problem and follow-up plan.
- Update the standard after a confirmed improvement.

Author: Sanjeewa Dehiwalage · Last reviewed: 2026-07-21