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Monday, July 11, 2016

Reprise: The Seven Basic Quality Tools

Pascal Dennis recently said that the so-called ‘Seven QC Tools’ aren't second nature to everybody. I couldn't agree more with Pascal. In that spirit, I'll describe these core tools & how they can help.

The Seven Basic Tools of Quality is a designation given to a fixed set of graphical techniques identified as being most helpful in troubleshooting issues related to quality. They are called basic because they are suitable for people with little formal training in statistics and because they can be used to solve the vast majority of quality-related issues.

The tools are:
  1. Check Sheets – A generic Tool which can be used for collection and analysis of data. A structured and prepared form that can be adapted for wide variety of issues
  2. Control Charts – This is a graphical technique,which can be used to study the changes to a process over time
  3. Pareto Chart – This is another graphical technique, which can be used to identify the significance of individual factors
  4. Scatter Chart – This is used to identify the relation between variables, by plotting pairs of numerical data, with one variable on each axis. The points will be falling on a line or a curve, if the variables are related.
  5. Cause and Effect Diagram (Also called as Ishikawa Diagram or Fishbone Diagram) – This can be used to structure the brain Storming Sessions. It is used to sort ideas into useful categories. Many Possible Causes are identified for a stated problem and the effect on the problem are identified
  6. Flow Chart (Stratification Charts) - This tool is used to identify the patterns within the data collected from multiple sources and clubbed together. It is used to identify the meaning of the vast data by identifying patterns.
  7. Histogram – It looks very much like a bar chart. it is used to identify the frequency of occurrence of a variable in a set of data.

The following presentation introduces the 7 basic quality tools:



Most organizations use quality tools for various purposes related to controlling and assuring quality. Although there are a good number of quality tools specific to certain domains, fields, and practices, some of the quality tools can be used across such domains. These quality tools are quite generic and can be applied to any condition.

The seven basic tools of quality can be used singularly or in tandem to investigate a process and identify areas for improvement, although they do not all necessarily need to be used. If a process is simple enough – or the solution obvious enough – any one may be all that is needed for improvement. They provide a means for doing so based on facts, not just personal knowledge, which of course can be tainted or inaccurate. Ishikawa advocated teaching these seven basic tools to every member of a company as a means to making quality endemic throughout the organization.


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Friday, July 8, 2016

Lean Quote: We Cannot Have Thinking Without Facts

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.

"We can have facts without thinking but we cannot have thinking without facts.— John Dewey

The general causes of troubles in factories arise from wrong knowledge and incorrect operations. To discern what is wrong and what is incorrect we have to launch into a fact finding process.

“The Facts.”

An overused expression.
Everybody assumes he knows, but no one actually knows.
One might be reminded of a story of the blind men touching an elephant and each reporting different description of what the elephant is.
One touches the trunk and talks only that, another touches the tail and describes the elephant as such.
Each believes his experience to be correct.
People often tell the stories from others as if they were their own experiences.

Discussions alone cannot eliminate troubles.
Words cannot always describe facts.
What is white may turn out as black.
Discussions cannot settle whether it is white or black.

“Let facts speak for themselves.”

With a humble attitude, carefully check things one by one.
At any rate what we are dealing with is a difficult thing.
It has an infinite number of features.
We must be aware that our knowledge and experience are finite, and always imperfect.
This recognition will make the facts appear.

A person who has engaged in a job for a long time is the one we call experienced.
As experienced person has a great deal of knowledge about that job.
These are correct knowledge and incorrect knowledge.
The problem is that he doesn’t know which is correct and which is wrong.
A true expert is the experienced person who is always furnishing his knowledge with facts, reflecting on that knowledge and making corrections.
Unfortunately, all persons with experience are not necessarily be true experts.
They can become encumbrances who bear superstitions.

We have to work diligently to find true knowledge.
It is just like in climbing a mountain road, you have to climb one step at a time.

After you’ve continued the climb for some time, you’ll suddenly realize how far you are above the starting point.


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Wednesday, July 6, 2016

Lean Tips Edition #97 (Tip # 1456 - 1470)

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 #1456 - Choose Courage Over Fear.
To be successful, you have to have courage. And to become courageous, do courageous things. Much of being successful is about going beyond what you think you're capable of -- venturing into the unknown. Whether you fail or succeed, you will learn and grow. Growth, in and of itself, means attaining a level of success whether it came from success or failure.

Lean Tip #1457 - Be Willing to Take Risks.
There are no guarantees on any path to success in life or business. The unknown is always looming. Therefore, risk and education are often the mechanisms necessary for knowing more clearly if you're on the right path.

If you're afraid to risk, you will put limits on your success and stay where you're comfortable. You cannot get what you want if you don't risk rejection and go for what you desire.

Lean Tip #1458 - Show Appreciation for Your Employees.
Workers who feel appreciated will be more motivated and productive. Praise employees publicly during meetings. Give spot awards. Profile employees and their work in company publications. If an employee puts in extra work on a project, recognize this. If you fail to reward hard work, your employees will not work as hard.

Lean Tip #1459 - Create a Culture of Accountability.
If workers are given ownership of their work and know they will receive feedback, they will work more meticulously. Accountability also means giving workers a clear sense of the direction of the company and how their work contributes to driving the company in that direction. If they feel like their work matters, rather than just being cogs in a huge machine, they will work harder.

Lean Tip #1460 - Invest in Training Your Employees.
All your employees will benefit from training, as it both makes them more valuable employees and creates a sense of indebtedness to the business, which leads to harder work. Pay particular attention to supervisors and middle managers who are just stepping into leadership roles. They are the key to transmitting upper management's vision and organizing work in an efficient manner, so extra management training for these positions will go a long way towards improving company productivity.

Lean Tip #1461 - Empower Your People
As you develop strong relationships you’ll see frontline employees wanting to step up. This is your opportunity to empower them. Encouraging authority, accountability, and responsibility at all levels creates a high performance team. Your role as leader is not to micromanage every detail of your organization but to rely on hundreds or thousands of people, each working toward a common purpose to be willing to make important decisions, exercise discretion, and answer for those choices. Let your employees know you trust them implicitly. They’ll earn it.

Lean Tip #1462 – Be Authentic, Share Yourself
One of the places most leaders fall down on the job is being inauthentic. They’re afraid to be vulnerable and known to others. Leadership has created a mental barrier that separates them from other people. Be honest about who you are, where you come from, and what you value. If you manage to practice all the previous strategies but don’t share your authentic self, you can’t build lasting relationships. Frontline leadership is about creating, reinforcing, and nurturing strong relationships.

Lean Tip #1463 – Expect Resistance to Change
Do not be surprised by resistance! Even if the solution a project presents is a wonderful improvement to a problem that has been plaguing employees, there will still be resistance to change. Comfort with the status quo is extraordinarily powerful. Fear of moving into an unknown future state creates anxiety and stress, even if the current state is painful. Project teams and change management teams should work to address resistance and mitigate it, but they should never be surprised by it.

Lean Tip #1464 – Seek Mentors.
Mentoring should be a necessity when it comes to planning out the improvement and development of future leaders. Mentoring is a popular idea for growth when it comes to leadership training. Make sure that your employees' mentor-mentee relationships don't just happen in a vacuum, however. One of the best benefits of mentoring is knowledge transfer, so give mentees and mentors structured ways to share what they've learned from these relationships. Successful employees have multiple mentors, so by building on that network effect, you allow leaders to branch and ultimately thrive.

Lean Tip #1465 - Lead With Passion, Not With Fear
Whether it be a good environment or a tumultuous one, leaders should never turn to invoking fear. In fact, in times of intense tension I believe that patience is even more important. Communication, clear objectives and performance feedback are critical in turbulent business environments but a fear-invoking boss can work to make bad situations worse. Lead your staff in an inspiring and passionate way – don't let their work be motivated by fear of your wrath. Remember intensity is different than fear. You can show passion but don't let it turn into intimidation.

Lean Tip #1466 - Have a Strong Lean Improvement Strategy
You'll need a solid plan and some attainable targets before implementing Lean. Utilize checklists and to-do lists, and you’ll always be working towards a goal. Look at every step in your process from the customer’s perspective: Is all that you’re doing something that he or she would be willing to pay for? If not, it is time to get back to the drawing board.

Lean Tip #1467 - Get the Whole Team on Board
To get the greatest advantages out of Lean, the entire organization should adopt and promote its practices, and extend its influence to suppliers as well. You must involve the people who are the closest to the work and you must get support from senior management as well.

In order to get people motivated, they must value the goals set for Lean manufacturing. These goals must be challenging, yet obtainable for your employees. Further, always ask for feedback on these goals, as well as progress toward target attainment. Feedback should always contain measureable facts and figures.

Lean Tip #1468 - Discard Conventional Fixed Ideas
Part of problem solving is thinking “outside of the box.” Encourage fresh perspectives and ingenuity in your team in order to develop innovative ways to forward Lean manufacturing without changing what is already efficient and successful. With such a rapidly evolving climate in manufacturing, sometimes conventional thought is what leads to the problem in the first place!

Lean Tip #1469 – Don’t Just Talk About it, Do it!
Once you have a Lean strategy in place, put it into fast and thorough action. Naturally, implementation is what ultimately yields results and improvement. The last think you want is to devise and formulate a Lean campaign that then sits on the shelf and collects dust. Run with your Lean plans as soon as you have everything nailed down.

Lean Tip #1470 - Concentrate on Bad Processes, Not People

By concentrating on the processes and building continuous improvement, you will have the culture change that you are looking for. Also, correct mistakes immediately. Don’t wait for the next shift, the weekend or maintenance to do it.

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Monday, July 4, 2016

Celebrating Independence and Lean Thinking


Independence Day, commonly known as the Fourth of July, is a federal holiday in the United States commemorating the adoption of the Declaration of Independence on July 4, 1776, declaring independence from the Kingdom of Great Britain. Independence Day is commonly associated with fireworks, parades, barbecues, carnivals, fairs, picnics, concerts, baseball games, family reunions, and political speeches and ceremonies, in addition to various other public and private events celebrating the history, government, and traditions of the United States.

Today, we celebrate and enjoy the freedom that comes with the event that made this day so special. Independence Day is a patriotic holiday for celebrating the positive aspects of the United States. Above all, people in the United States express and give thanks for the freedom and liberties fought by the first generation of many of today's Americans.

Freedom is not just the natural right of every human. It is the state of mind that enables people to create the greatest and the most inspiring things. The spirit of freedom gives us the power to conquer new heights, whether it is a real mountain peak or a bold business challenge.

Lean manufacturing provides your workforce the freedom that they need to own and maximize their productivity. In a Lean production plant, the "freedom to control one's work" replaces the "mind numbing stress" of mass production. Armed with the skills they need to control their environment workers have the opportunity to think actively even proactively to solve workplace problems.

Lean is all about finding better ways to do things, so that they require less effort, less time and fewer resources. It is not about cost reduction – penny-pinching, cutting investment, taking out people – it is about finding better ways to get work done. It is about developing a mindset, methods and tools to identify and eliminate waste in all its forms at every opportunity. It is about freeing-up resources because you no longer need to use them.

Lean Manufacturing is a business method that extends employees independence.  It provides more employees with the tools, methods and authority to make decisions. It creates teams to measure progress and devise new techniques. This leads to higher employee motivation and productivity

as workers are asked to come up with solutions to problems as opposed to having to work with flawed procedures. There is much to be said for greater worker independence in the execution of a lean philosophy. We may not have a day to celebrate like the US but the message is no less important.


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Friday, July 1, 2016

Lean Quote:Growth and Development of People is the Highest Calling of Leadership

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 growth and development of people is the highest calling of leadership.— Harvey S. Firestone

Your role as a leader is to develop talent to the highest levels of independent and autonomous thinking and execution. Great leaders don’t subscribe to a “Do-It-For-You” methodology of talent management, rather they lead, mentor, coach and develop team members by getting them to buy-into a “Do-It-Yourself” work ethic. Great leaders view each interaction, question or even conflict as a coaching opportunity. Don’t answer questions or solve problems just because you can, rather teach your employees how to do it for themselves. If you make it a habit of solving problems for people, you simply teach them to come to you for solutions at the first sign of a challenge.

Leaders facilitate the solution of problems by pinpointing responsibility and developing employees. Leaders do not solve other people’s problems. Similar to the fishing adage, which says don’t feed a person a fish; teach them how to fish, don’t solve the problem, teach them how to solve their own problems.

Lean thinkers at Toyota believe that showing respect for people means you allow them to think for themselves and solve their own problem. It is often said that the mission of Toyota is about developing exceptional people who happen to make great cars. The point is that it is more about people and less about the problem. The problem is another opportunity to teach them a skill for lifetime.


Develop exceptional people and teams who follow your company's philosophy. Empowerment happens when employees use the company tools to solve problems. Build cross functional teams to improve quality and productivity. Work hard to reinforce the company culture and assure it is followed over the course of years.



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Monday, June 27, 2016

There is No Silver Bullet But There is an Answer. Lean Thinking.



American businesses are undergoing its most profound transformation since the Industrial Revolution. Everyone is familiar with the litany of external marketplace factors causing chaos in American business – global competition, technology, and demographic and political changes. These have resulted in the elimination of millions of jobs, drastic restructuring, and new business relationships.

Most of us are either in denial about the impact of all this change, do not know what to do, or are still trying to figure out how we get back in control. Unfortunately, the result so far has been more of the same, a potpourri of programs designed to change the structure of our workplaces but not their essence – their culture. Downsizing, reengineering, and restructuring programs have succeeded in altering the employment base and cost structure of our companies, but do not offer us a new cultural framework. One round of structural change often leads to another, with the focus almost exclusively on the cost side of the ledger. In fact, structural changes often produce precisely the opposite result than intended by increasing instability, fear, and reduced productivity.

There is no silver bullet that will solve the complex of issues we face. Programs that focus on organizational effectiveness, empowerment, total quality, and/ or self-directed work teams provide a much more powerful tool for change. Lean Thinking is that program that can make all the difference.

Lean thinking changes the focus of management from optimizing separate technologies, assets, and vertical departments to optimizing the flow of products and services through entire value streams that flow horizontally across technologies, assets, and departments to customers. It encourages collaboration between customers, suppliers, employees and management in a positive approch to efficiency that spans the value chain.

Without this fundamental cultural change and the adoption of this new approach to leading and managing, American businesses will continue to experience significant difficulties in sustaining a competitive advantage.



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Friday, June 24, 2016

Lean Quote: Communication is the Glue that Binds an Organization Together

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.

"Ninety percent of leadership is the ability to communicate something people want.— Dianne Feinstein

Communication is the glue that binds an organization together but do not assume that several announcements and a note on the notice board is sufficient to get the story out. Some say to communicate seven times and seven ways but that does not mean seven months apart. Develop and implement a robust communication plan and check to see if the total target audience has received the unfiltered message. If you want to know if your message is getting out clearly why not ask the most obscure person on the night shift if he or she heard the message? The day shift is easy but how about the rest of the folks?

Open communication is at the center of Lean and Respect for People. Employees need to know what is expected of them and how they’re performing. Visual displays such as scoreboards, scheduling charts, team communication boards, and recognition displays all help to keep information flowing between employees, departments and upper management.

Communication is a key ingredient for empowerment. Give every employee equal and direct access to information. Many companies have developed a trickle-down style of communication that alienates those employees who may not be "in the loop." The more informed employees are and the more communication is open, honest, direct and complete, the more likely employees are to feel empowered and connected to the daily operations and overall goals of their company




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