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Wednesday, October 27, 2010

Lean Tips Edition #4


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Tuesday, October 26, 2010

Lean Product Development Process

I have the opportunity to present at the 2010 CONNSTEP Manufacturing & Business Conference on Novemebr 11.  The conference is built on continuous improvement and profitable growth – providing companies with the critical skills necessary to set a new direction and compete in the global recovery. With two keynotes and over 31 workshop opportunities, the conference will bring together leaders at every level and within every industry including manufacturing, healthcare and process based businesses.

Jamie Flinchbaugh will be the afternoon keynote speaker talking about changing behaviors through daily actions.  Mark Graban will also be presenting on how lean thinking helps hospitals.  I will be presenting on a Lean Product Development Process.

I thought I would share some of my thoughts on product development in terms of a Lean process.  Here is the abstract for my presentation:

Lean Product Development Process

Lean thinking is an enterprise strategy to grow your business profitably. For a business to grow profitably there are essentially two elements that are needed: Lean and Innovation. You need innovative products, technologies, and services that people really want. And this all needs to be done with operational excellence to compete in a global consumer driven market.

A Lean Product Development Process comprises 3 basic elements: (1) driving waste out of the product development process, (2) improving the way projects are executed with stage-gate A3 management process, and (3) visualizing the product development process.

The first step in eliminating waste from New Product Development (NPD), and thus improving the process, is to learn to identify the eight wastes.  By closely examining the entire NPD process from a Lean perspective, the opportunities to drive out waste and increase value will become obvious.

Improving the execution of individual activities with the use of Lean tools is the next step.  A stage-gate review process helps to define the process utilized in development while reducing the risk of development.  The A3 management process is used to solve problems, gain agreement, mentor, and lead projects.

The last step is to bring visual factory techniques to your product development process.  Visual boards displaying necessary information provides the status at a glance.  Stand-up meetings in combination with the visual boards allow for optimized communication and with a bias for action.

There are a number of best practices within the realm of Lean Product Development but with only 60 minutes I think this represents a practical place most organizations can start.  If you can do this successfully you will have the building blocks to grow your business profitably.

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Sunday, October 24, 2010

Exhilarating Learning - "Northeast" Shingo Style


Last week I spent a couple days at The Sixth Annual Northeast Shingo Prize Conference in Providence, RI.  The conference was an exhilarating learning experience for me so I thought I would share some of those nuggets with you.

It is probably makes the most sense to start with some thoughts from Ritsuo Shingo, son of Shigeo Shingo whom the prize is named after, since he started the conference.  Mr. Shingo talked about Lean management.  He encouraged the audience to do more than "Go and See" but rather "Go and Watch".  We must observe with a purpose.  Something he called "Genbaism".  Don't just take a plant tour.  That is what i would call MBWA (Mangament By Walking Around).  For me that is nothing more than a plant or department tour which doesn't encourage improvement or develop people.  All problem solving starts with grasping the facts.  To make this point Ritsuo asked the audience which is more serious a small fire or a big fire?  Well, it depends.  We need further information.  The question you need to ask is if you leave it alone what will happend next?  The most severe consequence is the bigger problem.  Ritsuo had a saying that really stuck with me, "Show them your back!"  This is really about the attitude you bring every day to everything you do.  Leader must lead by example.  Everyone is watching what you are doing. 

Mike Wroblewski had a great talk on kaizen improvement events.  There is no one size fits all.  Kaizen is really a means to involve the people of the organization in improvement.  The main goal of kaizen is to develop people to think Lean.  Mike used a teaching example that everyone can relate to in their daily lives.  Got Milk!  He asked the audience to explain lean concepts in terms of milk in their home.  An example I am going to have to use in my teaching. 

Alice Lee had an inspirational speak on both a personal and professional Lean journey.  She starts with a human development model which symbolizes a 3 legged stool - Tools, Philosophy, and Management.  The discussion centered around the philosophy needed to change from a traditional organization to a transitional organization through to a transformational organization.  There are several key elements needed to become a transformational organization:  1) Direction and focus 2) Disciplined approach, avoid distractions 3) Total participation (everyone) and 4) Strive for "True North". 

David Meier also talked about kaizen from personal experience.  He said human beings love tools and we know tools are easier to learn.  He says people often think kaizen mean quick or rapid improvement but that is not necessary.  The countermeasure must match the problem.  He challenge the audience to find solutions by asking what can be done right now.  Don't stop at the first solution continue to find another solution.  The first answer is not always the best answer.  Using PDCA ensure the problem is solved.  According to David the top 5 mistakes in Kaizen are: 1) Jumping to solutions 2) Bias toward a particular idea (usually your own) 3) Stop at first workable solution 4) Failure to deeply explore alternatives and 5) Continue to pursue an idea without merit.

Lesa Nichols says Muri is the new Muda.  If we get rid of Muri (overburden) which is caused by Mura (uneveness) we can get rid of muda (waste).  We tend to go about this in the wrong order.  We must look for the visual signs of Muri in the forms of physical and mental stress.  Look at the eyes, ears, fingers, back, neck, and shoulders to find Muri within your process. 

Bruce Hamilton, a.k.a. Mr. Toast, closed the conference by reminding Lean Thinkers about conceptual blindspots.  Where do we look for improvement?  Process improvement leads to operational improvement not the other way round. We often find apparent efficiency by being productive on things we don't need.  Don't automate the waste, eliminate the waste.  Bruce defined 3 steps for improvement:  1) Basic concepts 2) Systems to give shape to those concepts and 3) Techniques for implementing those systems.  He encouraged everyone to avoid being one of the 3 types of engineers Shingo despised:  1) Table Engineer - sits around table and discusses ideas 2) Catalog Engineer - looks in catalog and buys solution and 3) Not Engineer - says you can't do that.  Bruce encouraged us to be "Can Do Engineers".  He concluded with Dr. Shigeo Shingo words and the theme of the conference this year, "Easier, Better, Faster, and Cheaper."  As with everything Shingo did or said this order was deliberate.  We often make the mistake of starting backwards.  Make the job easier, then better, then faster and it will be cheaper.

The best part of the conference was meeting the truly wonderful Lean Thinkers.  There was about 550 Lean advocates and thinkers all together with one purpose and that was sharing best practices.  It is from this that we can all improve and raise the bar of Lean Thinking.  I had the pleasure of meeting some favorite Lean bloggers at the conference and you can see their take on the conference below: 

Shingo Prize winning author and blogger at Gemba Tales Mark Hamel on Easier, Better, Faster, and Cheaper.
 
Mike Wroblewski, who inspired me to start my own blog, from Got Boondoggle? wrote a couple pieces If air travel worked like healthcare, Inspired by Shingo again, and Lean bloggers at Shingo Conference.

and David Kasprzak who blogs at My Flexible Pencil, wrote a review from the conference like I did. 

I am already looking forward to next year's conference on October 5-6 in Springfield, MA. not only for the fact is 20 minutes from my house but for the people and the learning experience. 

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Friday, October 22, 2010

Lean Quote: The Two Dimensions 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.

"Outstanding leaders go out of the way to boost the self-esteem of their personnel.  If people believe in themselves, it's amazing what they can accomplish." --Sam Walton.

Some leaders are very task-oriented; they simply want to get things done. Others are very people-oriented; they want people to be happy. And others are a combination of the two. If you prefer to lead by setting and enforcing tight schedules, you tend to be more production-oriented (or task-oriented). If you make people your priority and try to accommodate employee needs, then you're more people-oriented. 

A popular framework for thinking about a leader's 'task versus person' orientation was developed by Robert Blake and Jane Mouton in the early 1960s. Called the Managerial Grid, or Leadership Grid, it plots the degree of task-centeredness versus person-centeredness and identifies five combinations as distinct leadership styles.

By plotting 'concern for production' against 'concern for people', the grid highlights how placing too much emphasis in one area at the expense of the other leads to low overall productivity. The model proposes that when both people and production concerns are high, employee engagement and productivity increases accordingly.

As Same Walton alludes the goal of effective leadership is to make others successful in performing their jobs!  Therefore consider where you place your concern.


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Tuesday, October 19, 2010

A Lean Environment is One Where They Present You With Solutions

I saw this comic at ONEFTE.com that made me pause a little. 


I know this comic is poking fun at the corporate lifestyle that many experience.  But as I reflected on this comic I thought to myself there are places in which this situation is true.  In a Lean Thinking organization it is the goal to have empowered employees to find problems and to provide solutions.  It is even encouraged that employees implement the solutions on their own. 

In previous posts (here and here) I talked about the Lean practices at FastCap.  They provide a great example where employees find problems and bring solutions.  Here is the latest example from FastCap's YouTube Channel about an office improvement:



So do you think there is a job where you get presented with solutions all day long?

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Monday, October 18, 2010

Lean Gone Lego - There must be a better way

I came across this short stop-animation film from Australia which delivers an insight into a better way of working in manufacturing called Lean gone Lego.



This video was developed by The Gordon, an online training company, supported by the Australian Flexible Learning Framework's E-learning Innovations business activity.  This project aims to empower workers to continuously come up with ideas to improve workplace productivity. 

While this is a fun video I think what is really intriguing is the use of Lean thinking in this project and in Australian manufacturing.  Lean aims to empower workers to continuously come up with ideas to improve workplace productivity.  For me there is no other answer.

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Friday, October 15, 2010

Lean Quote: Effective Listening

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.

"Of all the skills of leadership, listening is the most valuable—and one of the least understood. Most captains of industry listen only sometimes, and they remain ordinary leaders. But a few, the great ones, never stop listening. That's how they get word before anyone else of unseen problems and opportunities." — Peter Nulty, National Business Hall of Fame Fortune Magazine

The following keys are a positive guideline to better listeing.  In fact, they are at the heart of delevoping better listening habits that could last a lifetime.


Now the choice is yours.  Are you going to be a bad listener or a good listener?

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