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Tuesday, June 14, 2011

Daily Lean Tips Edition #15

For my Facebook fans you already know about this great feature. But for those of you that are not connected to A Lean Journey on Facebook or Twitter I post daily a feature I call Lean Tips.  It is meant to be advice, things I learned from experience, and some knowledge tidbits about Lean to help you along your journey.  Another great reason to like A Lean Journey on Facebook.

Here is the next addition of tips from the Facebook page:

Lean Tip #211 - Set aside time for talking with your team about expectations.

You as the leader need not have all the answers. Your role is to ensure that the process for setting the expectations is clear and followed. Involve the people who do the routine work in defining the desired outcomes and the methods by which the results will be accomplished. You and the person(s) accepting the responsibility should build in from the beginning some agreeable method for routinely reporting progress.

Lean Tip #212 - Setting clear employee expectations is a key component in employee performance.

Explain, in detail, what is expected of them. Employee performance management requires that expectations are continually updated and communicated. Communicate what employees can expect from you as the team leader. Inform employees of what colleagues can expect from one another.

Lean Tip #213 - Successful leaders help employees find their full potential and guide them toward desired outcomes.

Keep your focus on the desired outcomes, not on describing each and every step to follow. You as the leader need not have all the answers. Your goal is to guide, not control. Letting individuals find their own route toward productive outcomes encourages them to use their strengths to their fullest potential.

Lean Tip #214 - Ensure your expectations are in alignment with your employees expectations.

Setting clear expectatios is not enough. You must ensure these expectations are cascaded through the organization. Ask your employees to list what they think is expected of them and tell them you will do the same. Compare the two lists to see how effectively you set expectations and how they understand them.

Lean Tip #215 - Good expectations are nothing without the right knowledge, skills, and competencies.

Performance problems may occur when a supervisor and employee lack agreement about expectations or lack the skills to meet the expectation. Expectations are the" know-what" where as skills are the "know-how". Leaders must provide employees the right tools and skills to be successful. Given the changing nature of work assessing the required knowledge, skills, and competencies, and then providing appropriate training and development is critical for good performance.

Lean Tip #216 - Metrics drive behavior, and the wrong metrics drive the wrong behavior.

Direct labor productivity is not a good metric. It doesn't matter whether each worker is producing as much as possible. What matters is whether the plant is producing the amount of product the customer wants. And that is not the same thing. Don't talk about direct labor productivity.

Lean Tip #217 - Without properly focused metrics you won't see performance as it really is or could be.

Management that focuses on the wrong metrics see processes as they think they are. For example, if plant management is totally focussed on shipping dollars, efficiency, utilization, and overhead absorption metrics then they miss reducing cycle time and increasing customer satisfaction. This can lead you to make less than optimal decisions.

Lean tip #218 - It is very difficult to improve something that you fail to measure properly.

Without good performance measurements, it is easy for companies to fall into a very common trap: Employees keep busy with all kinds of activities but achieve few of the desired results. Effective performance measurement is the compass that guides management toward meaningful results at the process level, results that will tie directly with the company's goals

Lean Tip #219 - Metrics should be implemented to influence or regulate our processes and our actions.

If what you measure doesn't change behavior or enable you to make a decision, why are you bothering to measure it? The best metrics are those that impact our processes. Yet you would be surprised how few of the metrics affect the things we do.

Lean Tip #220 - Focus on proactive metrics that measure the right things.

The overwhelming bulk of metrics are what I call "comfort metrics." They tell us, or our bosses, that we have done a good job. But our focus should be on proactive metrics - that is, the right metrics. That means that the right person sees the right metric at the right time so that he or she can take the right action to achieve the right result.

Lean Tip #221 - Continuous Learning Creates Endless Opportunities

A constant quest for learning provides the means to always be moving forward, to conquer new frontiers and achieve new and exciting goals. Make a point to learn something new every day. Learning new things brings more exciting experiences your way. It allows you to meet other people who can bring further knowledge or learning opportunities.

Lean Tip #222 - Set Learning Goals to Further Your Knowledge

We usually set goals for the year around performance at work or weight loss/exercise at home. You should also set goals around learning. Try to learn a new skill every year. By creating a plan for learning and measuring your progress you can be sure to achieve the goal. This will create a continuous learning cycle.

Lean Tip #223 - Continuous Learning Isn't Possible Without Practice and Experimentation

Continuous learning requires two elements to be truly successful overtime:

PRACTICE: After completing a learning experience, create opportunities to apply what you learned as soon as possible and many times to refine your ability.

EXPERIMENT: Take a risk and try something new, even if you aren’t all that comfortable. We can learn as much,sometimes more, from our mistakes than from getting it right the first time.

Lean Tip# 224 - One of the best ways to learn is to teach or coach someone else

One of the best ways to learn is to teach or coach someone else. Most trainers will tell you that they

learned a lot more from teaching than from taking courses themselves. Share what you are learning with a coworker; offer to coach someone who is learning a new skill; agree to do deliver a workshop.


Try blogging - this has been a truly remarkable learning experience.

Lean Tip #225 -Successful Companies Build a Learning Organization

Learning is the key to success—some would even say survival—in today’s organizations. Knowledge should be continuously enriched through both internal and external learning. For this to happen, it is necessary to support and energize organization, people, knowledge, and technology for learning. A learning organization values the role that learning can play in developing organizational effectiveness.


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Monday, June 13, 2011

A Tribute to Eli Goldratt



This weekend a true pioneer in process and business improvement passed away. From the Goldratt-TOC website:

It is with great sadness we announce the passing of Dr. Eli Goldratt the founder of TOC. Eli passed away on 11 June 2011.

"I smile and start to count on my fingers: One, people are good. Two, every conflict can be removed. Three, every situation, no matter how complex it initially looks, is exceedingly simple. Four, every situation can be substantially improved; even the sky is not the limit. Five, every person can reach a full life. Six, there is always a win-win solution. Shall I continue to count?"

Dr. Eliyahu M. Goldratt 1947- 2011


The Goal was one of the first books I read early in my career.  I highly recommend this book for anyone involved in process improvement. 

In a tribute to Eli Goldratt I thought I would share some posts I did highlighting his teachings:

Lean Quote: Change: Isn't it Obvious 
Do you know how to handle your constraint?
Lean Quote: The Bottleneck 
The Eight Wastes of NPD 
Is it the End of an Era or Just another Lesson? 

Even though this Guru has passed his lessons will continue for generations.  Who could forget the lessons of "Herbie" and that of problem solving.  

How did Eli impact your Lean thinking? Share you story here.


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Friday, June 10, 2011

Lean Quote: Lean Requires Patience, Practice, Sharing

On Fridays I will post a Lean related Quote. Throughout our lifetimes many people touch our lives and leave us with words of wisdom. These can both be a source of new learning and also a point to pause and reflect upon lessons we have learned. Within Lean active learning is an important aspect on this journey because without learning we can not improve.

"The practice of patience toward one another, the overlooking of one another's defects, and the bearing of one another's burdens is the most elementary condition of all human and social activity in the family, in the professions, and in society." — Lawrence Lovasik


The other day I saw this video on TV that had a compelling message that relates to the approach we need to take when implementing Lean.

Based on a true story, this poignant moment in a concert hall reminds us how even the most embarrassing situations can be turned around with a little patience and encouragement.

Click picture to go to video.

From Values.com Patience, Practice, and Sharing can be defined as:

Patience is the capacity to accept or tolerate delay, trouble, or suffering without getting angry or upset. 

Practice is a learning method that can lead to perfection.

Sharing is having a portion of something with another or others.

The Foundation for a Better Life began as a simple idea to promote positive values. They believe that people are basically good and just need a reminder. And that the values we live by are worth more when we pass them on.

Lean thinking is difficult transition to make in many organizations.  From dealing with naysayers to finding early supporters to help convert the rest the challenge is the same.  If you can reflect back on this video's message and that of the quote it will help you in this transition.  Lean thinking requires patience, practice, and sharing to be successful.  Build confidence through encouragement.



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Wednesday, June 8, 2011

Who Wants To Be A Lean Millionaire


A couple weeks ago at EASTEC my friends at GBMP held a unique learning opportunity.  The idea was to combine the format of the Millionaire game show with Lean thinking.  This trivia game was complete with the help of 50:50, phone a friend, and the poll.  They had several levels from beginner to advanced so everyone could participate in the fun.


If you were able to answer all the questions then you won this t-shirt:


GBMP is always finding creative ways to teach Lean thinking from their Toast Kaizen Video (which they did in person at the show last year) to their hands on exercises.  If you want more you should attend the Northeast Shingo Prize Conference this fall.  I had a great experience last year and I look forward to this year's conference.  The theme is about showing how and why America can regain a leadership position for productivity and quality in a global marketplace.




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Tuesday, June 7, 2011

Lessons For Turning Crisis Into Opportunity

Toyota Under Fire: Lessons for Turning Crisis into Opportunity
Toyota Under Fire takes you beyond the headlines and into the offices and factories of Toyota to reveal the truth behind the company's highly publicized and controversial recall of nine million vehicles last year.

Jeffery Liker, the author of Toyota Way, and Timothy Ogden co-author this historic case study providing new insight into Toyota's culture. Toyota Under Fire chronicles the events of the recession and the recall crisis in detail, providing valuable lessons any business leader can use to survive and thrive in a crisis, no matter how large:
  • Crisis response must start by building a strong culture long before the crisis hits.
  • Culture matters far more than decisions made by top executives.
  • Investing in people, even in the depths of a recession, is the surest path to long-term profitability.

The books consists of five roughly chronological chapters:

1.      The Most Admired Company in the World
2.      The Oil Crisis and the Great Recession
3.      The Recall Crisis
4.      Response and the Road to Recovery
5.      Lessons

This book provides a clear account of the crisis amid a litany of heresy.   They get to the truth by going to the source, or what we call genchi gunbutsu - go and see for yourself to learn what is really going on.  Toyota Under Fire is a very well researched and detailed book.

I particularly enjoyed the last chapter where Jeff and Tim provide a comprehensive analysis of what others can learn from Toyota about crisis management and turning crisis into opportunity. They summarize four main lessons to be learned from how this crisis was handled:

Lesson 1: Your Crisis Response Started Yesterday
Turning crisis into opportunity is all about culture. It's not about PR strategies, or charismatic leadership, or vision, or any specific action by any individual. It's about the actions that have been programmed into the individuals and teams that make up a company before the crisis starts.

Lesson 2: A Culture of Responsibility Will Always Beat a Culture of Finger-Pointing
By not pointing fingers Toyota was able to turn the energy from the crisis from anger or despair to positive improvement energy. The starting point was to take care of customers. Then energy turned to looking in each function and finding opportunities for improvement to respond more quickly to every customer concern, whether rooted in technical defects or customer perception.

Lesson 3: Even the Best Culture Develops Weaknesses
Toyota's investment in a shared culture of continuous improvement is remarkable and practically unique.  But, the company still encountered difficulties that were directly attributable to weaknesses in their culture.  The greatest threat to a culture of continuous improvement is success.

Lesson 4: Globalizing Culture Means a Constant Balancing Act
Developing a shared corporate culture across varied national cultures is perhaps the biggest challenge facing modern multinational corporations.  The balance between centralized and decentralized, global and local is even harder than most people think.  It was out of this balance toward too much centralization and where they took bold actions to provide more power and influence to local leaders.

Challenge is the source of energy to go beyond goodness to greatness.  After a crisis the goal is never a steady state of returning to the status quo.  That's perhaps the final and most important lesson of turning a crisis into an opportunity.

Toyota Under Fire is highly recommended business leaders, Lean thinkers, and those interested in learning from crisis management.  I believe the message of this book will serve as an essential lesson on the importance business culture and crisis management for all students of business.

Get Yours Today!


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Monday, June 6, 2011

Lean Practiced at Your Home Away From Home

Many Lean practitioner remark about the examples of Lean thinking they find in their travels.  I recently had a trip away from home for training (USA hockey Coaches training) where I found some examples worth sharing.


Here is a good example of a simple poka yoke and standard work posted at point of use. So first of all the black disc is heavy like paper weight so it keeps the cord on the desk where you want it.  They slide a simple rubber grommet over the connector to prevent the cord from sliding through the hole in the black disc.  The disc has the instructions printed on it so that you can easily connect to the internet.


Here is an example of a kanban signal.  Hotels try to conserve energy and water by reducing the number of laundry runs.  They do this by giving the hotel guest the option to use their towels and linens  multiple times if they stay multiple nights.  So in this case you place this card on the bed if you want to tell the hotel maid to change the linens or towels.  It signals replenishment from their inventory of clean linens.  On the back of the card (not pictured) are the instructions explaining this process.


Here is an example of point of use storage and standard work instructions.  Next to the coffee machine in the room are the coffee supplies.  Everything you need is neatly stored in one place.  All coffee machines are different so the hotel has printed and placed instructions for operating this machine locally to avoid confusion.


The last example is that of a visual indicator.  This placard can be put on your door to indicate that you are still sleeping in your room and you don't want to be interrupted.  By placing this signal on the door the maid knows to skip your room and go to the next available room.

These examples which are common in many hotels certainly make traveling and staying away from home easier.  You can also see how it helps the hotel provide the service you need during your stay. As a Lean practitioner I am always interested in examples of Lean thinking. They can serve as great learning opportunities.  We are often surrounded by them but struggle to recognize them. Can you recognize Lean thinking around you?


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Friday, June 3, 2011

Lean Quote: Cure the Fear with Learning

On Fridays I will post a Lean related Quote. Throughout our lifetimes many people touch our lives and leave us with words of wisdom. These can both be a source of new learning and also a point to pause and reflect upon lessons we have learned. Within Lean active learning is an important aspect on this journey because without learning we can not improve.

Most people would rather live with a problem they can’t solve than accept a solution they can’t understand." — R.E.D. Woolsey and H.S. Swanson

Fear of unknown, consequent failure and complacency are some of the major reasons for resisting change. There are some people out there who have no fear of the unknown, and who can simply decide logically what they want to do and do it, but for the rest of us, we have to make the unfamiliar feel familiar.

This fear can be diffused through open discussion and successful improvement events. Employees will go along with change more readily if they feel responsible for its implementation. Few people oppose something they helped develop. Employees’ involvement in successful endeavors will motivate others in the facility to join the journey and begin to implement change on their own. Ask employees for their time, ideas, and suggestions to make certain that a positive environment for change is created. Change is best done through reasonable increments and initial successes. Let people be active participants and become responsible for the new way of doing things.

People are normally very open to new solutions which they are familiar with or which they know they can easily understand and learn, but are averse to the opposite. Make the unfamiliar familiar through effective learning. You will find this is not dependent on how hard or easy the solution is to learn but how well the solution and method for learning/embracing is presented. One of the best ways to bring this about is to involve the people in the solution finding process, being receptive to their feedback on the problem, and the prospective solutions they are looking at.

Going ahead with implementing a solution that the people don't understand will not do anyone any good. Forcing them to accept and learn it will only make them rebellious and resentful. Consequently, they will rather live with the problem than work to resolve it.

I have learned the fear of the unknown is natural and we must overcome this fear through learning and understanding.


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