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Friday, April 1, 2011

Lean Quote: Combating De-Motivation in the Workplace

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.

"There are no hopeless situations; there are only men who have grown hopeless about them." — Clare Boothe Luce

The choices you make everyday influence the motivational climate of your company. As a manager you want to create a motivated workplace. It is equally important to know what actions to avoid so you don't de-motivate. Managers and other organizational leaders often make the following crucial mistakes, which lead to low morale and workplace de-motivation:

  • Criticizing in front of others
  • Being dishonest
  • Taking credit for others' work
  • Being inaccessible
  • Showing favoritism
  • Delegating without giving authority, or delegating to the wrong person
  • Communicating poorly or failing to communicate at all
  • Failing to train employees for job responsibilities
  • Exhibiting wishy-washy behavior
  • Failing to emphasize teamwork
  • Giving the impression that you're concerned only about your own well-being
  • Displaying poor personal work habits such as disorganization and procrastination
  • Tolerating poor performance
  • Over supervising
  • Imposing impossible workloads
  • Focusing only on negatives 



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Tuesday, March 29, 2011

The Speed of Improvement

In an earlier post I talked about "The Lean Way to Tie Your Shoes" which illustrates the fastest method to tie your shoe. This post highlighted a number of lean lessons for everyone. A similar cleaver video also demonstrates a number of lean lessons. Before you look at the video let's examine those lessons:

1. Recognition of time as a valuable asset. We don't want to waste our time.
2. Making improvements in things we do everyday. Something Paul Akers calls "improvement in what bugs you."

3. Visual cues are important in demonstrations for accentuating your point.
4. Solutions don't need to be complicated nor require technology to be successful.
5. Sharing best practices with others helps them learn to solve their problems.



What do you think? Is this video a good example of everyday Lean Thinking?


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Monday, March 28, 2011

Cultivating Empowered Employees

To "empower" means "to allow or enable."  Successful leaders conduct themselves in such a way that employees feel good about working with them.  How do they do this?  By enabling and allowing employees to succeed.  Empowered employees feel ownership for their work, a critical element  to creating a motivated workplace.  The ten steps that follow are necessary to cultivating empowered employees.

1. Delegate meaningful jobs, not just the "junk" stuff you don't want to do. Workers don't want to perform trivial tasks on a regular basis any more than you do. If the tasks are truly unimportant, maybe they should be deleted altogether. If they are necessary, consider setting up a rotating schedule so workers can take turns performing the task.

2. "Let go" once you delegate (supervisors have a tendency to oversupervise). If you delegate a task, make sure the person you give it to has the skills, the instructions, and the resources necessary to carry it out. If you don't have the confidence in the person's ability to do a satisfactory job, you shouldn't give the task to that person to begin with.

3. Show you trust your employees by accepting their ideas and suggestions. Seek out employees' ideas on a regular basis. Employees feel ownership of a process or a task when they've had input into it.

4. Whenever possible, provide opportunities for employees to work in self-managed or self-directed work teams. Allow these teams freedom to determine the best course of action for meeting agreed-upon goals and objectives. Employees will see firsthand the results of there decisions and feel the pride of group achievement.

5. Give credit where credit is due. A sure way to earn distrust from employees and squelch their enthusiasm is to take credit for their good ideas and performances.

6. Create opportunities to showcase your employees. "Billboard" employees to your own supervisors and to others in upper management as well as to those outside your department or division. Some managers erroneously think that if they give workers credit, upper management will question the manager's own performance. But managers who fall into the trap of competing with the employees they supervise usually stall their own careers.

7. Add interest and challenge to workers' day-to-day routines by implementing job rotation. Job rotation simply involves placing employees into jobs of equal value that they may have expressed an interest in or that you expect, based on their skill strengths, they may do well in. Some organizations encourage employees to initiate job rotation through a formal process, thereby increasing job skill levels as well as motivation.

8. Provide employees with responsibility and authority to successfully accomplish assignments. Today, progressive companies utilize the skills and talents of their employees by assigning them to cross-functional or self-directed work teams. Employees not only perform their own specific job functions by have a team identity as well. Team members are responsible and accountable to the team for achieving its goal, implementing processes, and sharing the recognition for its results.

9. Provide assistance to employees without taking away responsibility to complete the job. Clearly define your role and avoid the temptation to do the job yourself when employees find themselves in hot water. Let employees go it on their own and face those gut-wrenching challenges.

10. Find ways to foster employee self-esteem and self-confidence. Although important, managers and supervisors must do more than give praise and provide meaningful work. To empower employees, supervisors must continually build employee self-esteem.



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Friday, March 25, 2011

Lean Quote: Carrots and Sticks

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 could probably win more often if we were willing to deploy seasoned personnel and equip them with sufficient carrots and sticks." — Thomas M. Fran


Motivation is a core factor for a successful business and there have been many studies around it, yet there is no definitive answer or a one size fits all solution to motivation and employee engagement. The several elements of motivation differ from person to person as well as circumstances.

A well known motivational concept is the “Carrot and Stick” approach. This analogy is about using rewards and penalties in order to obtain desired results. It refers to the old story that in order to get a donkey to move forward and pull the cart you would dangle a carrot in front of him or hit him with a stick from behind. The result is the same; the horse moves forward.

So the stick represents fear, which can be a good motivator when used sparingly at the right time. It may produce immediate results that derive from prompt compliance. It is only useful in the short term though, as over time increasing levels of punishment would be necessary to obtain the same results and this can backfire in the form of mutiny and sabotage.

The carrot is then an incentive, which can work very well as long as the individual finds the incentive appealing. In this case, the donkey would have to like carrots, be hungry and/or have a manageable and movable load in order for the carrot to work. This is very important as the incentive must be perceived to be attractive enough.

Reward and punishment are significant motivators only if the reward is large enough or the punishment sufficiently severe. For example, management holds out a carrot, offering a week’s paid vacation to the person who has the highest production numbers. Employees will work hard to reach that target (if the vacation is really what they want), but once the contest is over, they will revert back to their previous level of effort. Or, management wields a stick, threatening some kind of punishment if employees don’t do their jobs. In those cases, people will do just enough to “stay under the radar” and avoid getting into trouble. While some carrots and sticks may work in crisis situations or as a stop-gap remedy, what they mostly do is promote nearsighted thinking, mistrust, cynicism, and a diminished capacity to innovate and create.

Typically, organizations tend to base their motivational schemes on tangible good such as money, in the form of pay and bonuses. The problem with this, like the carrot, is that its attractiveness decreases over time. Sometimes, a simple word of praise from your boss can mean more than a small pay rise. If organizations could find the perfect balance been tangible and intangible rewards, carrots and sticks, this would be the answer to the motivation question. Managers must not overlook these motivators if they want to retain staff and more importantly, have them working to the best of their ability.


If you’re looking for ways to create an environment where people are driven to do their best work, you’ll need to think beyond carrots and sticks. It’s a bit trickier, perhaps a little messier, but if you want to create a thriving organization, you’ll need to consider motivation from the inside out.

What motivates you at work? How do you motivate others?



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Thursday, March 24, 2011

Lean and Metrics The FastCap Way

Paul Akers from FastCap answers the question from a follower on what Lean is and what metrics you measure in a Lean environment. Paul’s response is a great one and worth repeating. The following key points summarize Lean and Lean Metrics:

1) Make Lean so simple anyone can understand it.
2) Fix what bugs you and improve it everyday.
3) Every employee must make a 2 sec improvement everyday.
4) People fail sometimes and solutions may not valid but you learn from that.
5) Create a routine like: start day with Sweep, Sort, Standardize, then improvement time, then morning meeting.
6) Give people time everyday to experiment, train, and teach.
7) Simple metrics –
           a) 1 improvement everyday
           b) Orders out in 2 hours
           c) Less than 1 mistake a week
           d) Want customers to rave about us
8) Defects are something the customer sees.
9) Develop the skill and capacity to solve problems by everyone everyday.

Here is Paul in his own words:



Paul says he likes Lean compared to other methodologies because it is focused on the individual, respect for their creativity, and brings them into the process on a daily basis.

What do you think? Did Paul Akers get it right?


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Wednesday, March 23, 2011

TPS: The Source of Human Progress

While on the internet the other day I came across these videos explaining the history of the Toyota Production System.  They appear to be from an older video that has been edited and then subtitled in Portuguese (I believe).  I think I had seen the original video before on the Art of Lean provided by Art Smalley.  Still learning about the history of the Toyota Production System can provide a look at the progress of manufacturing by human thinking.





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Tuesday, March 22, 2011

Daily Lean Tips Editions #11

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 #151 - The following three points are extremely important in establishing standard work.


The following three points are extremely important in establishing standard work:

The reality of the shop floor is clearly reflected in standard work.
Standard work must be realistic and applicable to the shop floor.
Standard work must lead to continuous improvement opportunities.

Lean Tip #152 - We must ask why the standard work times are not being met

Always ask youself "Why?" repeatedly while observing the shop floor in detail. Ask questions like,"Why is work performed in a certain way?", "Why are workers moving in a wasteful manner?" and "Why are we have trouble reducing standard work time?" Then, start thinking firmly about what you can do to improve the situation.

Lean Tip #153 - If there is a problem, go to the actual place and solve it if you want to get things done.

If there is a problem, go to the actual place and solve it instead of just criticizing it as if it does not concern you at all. This is one of the most fundamental practices that we can do to facilitate the ability to get things done.

Lean Tip #154 - Ideas are different from knowledge.

Ideas are different from knowledge. Anyone can aquire knowledge by reading books or attending school. In other words, knowledge can be readily purchased. On the other hand, ideas are aquired by ones own experience. You must apply your knowledge to create ideas.

Lean Tip #155 - Fix the problem immediately and move on.

Some managers point out a problem to workers and leave it to them until it is solved. This does not motivate workers to fix the problem right away. Taiichi Ohn always made sure his workers:

Fixed the problem immediately after it was identified.
Confirmed the result with their own eyes.
Ignoring problems means the waste remains in production affecting your process.

Lean Tip #156 - Visit the work area to understand and monitor improvement plans.

What can you tell at a glance? Here are some ideas to focus on:

What items are being worked on?
What items should be worked on?
What is the expected and acutal production rate?
What problems are the workers having?
How many people are needed?

Lean Tip #156 - Visit the work area to understand and monitor improvement plans.

What can you tell at a glance? Here are some ideas to focus on:

What items are being worked on?
What items should be worked on?
What is the expected and acutal production rate?
What problems are the workers having?
How many people are needed?

Lean Tip #157 - Make standards visually apparent to satisfy the customers need.

At a glance, employees and management should be able to tell what the customers need and what rate of production is needed to meet this. Any reason that the standards cannot be met should be visually apparent, so the problems can be solved immediately.

Lean tip #158 - Lean Tools can help create clear standards but they also need to be sustained.

Tools like 5S, standardized work, set-up reduction, and pull systems/kanban all help create a clear, standard work environment. But if these standards slip, then they quickly cease to become standards. Employees then become cynical about improvement and it slows down or stops.

Lean Tip #159 - Problem escalation should not be viewed as a sign of weakness.

Problem escalation should not be viewed as a sign of weakness. If an employee cannot handle a problem without assistance, he or she should ask for and count on management support. Making problems visible and solving them immediately should feel normal if you want to improve.

Lean Tip #160 - An effective idea system is not about the amount of savings obtained.

An effective idea system is not about how much savings are obtained from the ideas put forth. Typically we have many small problems compromising material and information flow throughout our companies, so it is many many small ideas that we are looking for.

Lean Tip #161 - Answer three questions to determine an inventory strategy for your pull system.

To implement an inventory strategy based on pull of the customer you need to determine three things:

How much inventory will you keep?
Where will you keep the inventory?
How will you replenish inventory based on customer pull?

Lean Tip #162 - Not all stock is the same, changes in demand requires different types of stock.

There are three types of inventory to consider:

Cycle stock: This is the minimum amount of goods being built for the next shipment and protects against average daily demand and demand through replenishment time.

Buffer Stock: These are goods held to protect against predictable common-cause variation in demand.

Safety Stock: These are goods held at any position in the stream to protect against unpredictable special-cause variation in demand.

Lean Tip #163 - Separating your stock can help you understand the source of abnormal inventory.

Separating inventory into buffer stock (to absorb customer variation) and safety stock (to absorb supply variation) aids in problem-solving by identifying the source of the cause of abnormal inventory (overstock or understock).

Lean Tip #164 - Reduce incoming and outgoing inspections to create flow in your supply chain.

Material (and information) should flow uninterrupted from suppliers to customers in a Lean supply chain. Shipping and receiving inspections are nonvalue-added processes and should be eliminated. To do this you will need quality-at-the-source and error-proofing.

Lean Tip #165 - Beware of Forecasting and Marketing Strategies When Looking at Consumption

When researching customer consumption, be sure to review forecasting and marketing strategies. Price discounting or promotions designed to push product into the marketplace will appear to increase ‘consumption” in the short run, but this rarely last for any extended period. Models that use historical data to forecast future consumption also can give inaccurate guidance.


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