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Monday, June 20, 2011

Pull Systems: An Essential Lean Element

The Association For Manufacturing Excellence (AME) is committed to enterprise excellence through shared learning and access to best practices.  As a proud member and leader in the Northeast Region I had the opportunity to share a best practice last fall on pull systems.  I have talked about this pull system before but AME recently published an article in Target Magazine about this event that you should read.

The article was written by Jeff Schaller, a professor of operations management at Eastern Connecticut State University.  In brief: 
Mercury Wire and OFS share their experiences and learnings from implementing lean and pull systems. Strategies and results at each company vary; commonalities include their focus on providing customer value, nurturing cultural change, and continuing performance improvements.


At a recent two-day AME “kick the tires” workshop held in Massachusetts, two companies, Mercury Wire and OFS, showcased their lean implementations and the pull systems used in their facilities. They also shared their approaches to teaching and training employees about the benefits of pull systems, and one of the companies showed how they have applied pull concepts to project management. This article provides a description of pull system basics, followed by an explanation of how the companies utilize their pull systems as a key element in implementing the lean philosophy.
Tim McMahon, OFS lean manufacturing leader, presented value stream maps for OFS Sturbridge’s old push system and the current pull system (see the accompanying illustration).



OFS Sturbridge has gone beyond using this approach to facilitate timely production and material transfers between processes. Increased visibility across the processes allowed the facility to develop teamwork for identifying and eliminating workload imbalances between the processes, helping to reduce backlogs.

Both organizations view pull signals and pull scheduling methods not just as tools but as part of a larger lean philosophy that is used to solve problems and serve customers.

There is a lot of valuable information in this article that goes well beyond the simplicity of pull.  Hopefully you can see applications for pull systems in your organization beyond just material. This should also give you an inside view to what I do as a Lean Practitioner in manufacturing.


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Friday, June 17, 2011

Lean Quote: Inspiration

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 one extra degree of effort in business and in life. Separates the good from the great." — Unknown


At 211 degrees, water is hot.
At 212 degrees, it boils.
And with boiling water comes steam.
And steam can power a locomotive.
So many times it is that one extra degree of effort in business and in life that separates the good from the great.
The beauty of 212° is not only the simplicity but also the many applications. You can apply the concept to 212° service, 212° attitude, 212° leadership, 212° kindness, 212° commitment, 212° focus, 212° perseverance and the list goes on. Whatever your passion or profession, how true it is!





The next time you or your team needs inspiration refer back to this video's message:

It's your life.  You are responsible for the results. To get what we have never had we must do what we have never done.


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Thursday, June 16, 2011

Lean Lessons From The Stanley Cup Winning Boston Bruins

Many of you know of my enthusiasm for Ice Hockey as a player and a coach.  In the last few weeks hockey fans from all over the world have been captivated by the Stanley Cup Championship Playoff between The Boston Bruins (my team) and The Vancouver Canucks. This is the pinnacle of the hockey season with the winner taking the oldest professional sports trophy in North America.

As I reflect on the accomplishments of another season coming to an end I can't help but think about the valuable lessons that have been demonstrated.  I will present these ten lessons in terms of Lean thinking.

  1. Winning requires a positive attitude.  There are a lot of things out of our control and adversity is part of the challenge but how we react is up to us.  The right attitude can keep you moving forward.  The Bruins never dwelled on what they did wrong but what they needed to do better for the next game. 
Lean requires a willingness to try something new to improve our workplace. Fix what bugs up. Make work easier.

  1. Never give up.  Sports have lots of highs and lows throughout the game.  Perseverance is necessary to turn a bad situation into a good situation. When the Bruins were behind they never gave up and that kept them in the playoffs. 
Lean also needs perseverance to get you through the difficult bumps in the road along the way to improvement.

  1. Use a system.  All professional sports teams use a system.  It is more than set plays but methods in which the team works to beat their opponent. This ensures that everyone executes together.  The Bruins system involved a defense first approach and not looking behind the next shift. 
Systems and processes are at the heart of Lean thinking as they are the key to establishing standard work. This allows us to easily detect abnormalities and make improvements.

  1. Don't change for the sake of changing.  When the Bruins were struggling people were quick to suggest and ask what changes were needed.  Their Coach Claude Julien stayed the course and said don't panic.  It worked for them all year so there is no sense in changing everything when you are down.  If he had changed this late in the season it could likely have been worse. 
Changing just to change isn't necessarily productive but change based on real need is warranted. Following a PDCA process ensures you change when you need to.

  1. Practice. Practice. Practice.  All sports teams practice and the Bruins are no exception.  The key to their practices is to focus on game situations.  This high speed sport is much about reading and reacting so you must practice with intensity if you want to play with intensity.
In your organization you may not necessarily call it practice but you certainly experiment.  This experimentation is what prepares us to solve more and more complex problems.

  1. Find a leader.  Coach Julien has taken the Bruins from last place in the Northeast Division to four straight playoff appearances. You also need strong team leaders like that of Captain Zdeno Chara.
Leadership is essential in all organizations but in a Lean organization the leaders play a critical role of developing and empowering the people within the system.

  1. Take time to reflect.  Coach Julien was recently asked if he had taken time to take in the moment of being in the playoffs.  He said if you want to remember the moments you must stop and live in the moment. 
In Lean we call this reflection Hansei.  It is this process that makes learning and improvement possible.  We must take time to reflect on where we have been and how we did it if we want to move past it.

  1. It can take a long time to reach your goal.  The last time the Bruins won the Stanley cup was in 1970 (41 years) and the last time they made it to the final round of the playoffs was 1990 (21 years). Their goal as an organization has been to win the cup and over the last 10 years or so they have been on a mission to get back to the finals.
The Lean journey in pursuit of True North is a quest that also takes a long time with lots of patience and persistence.  Don't lose sight of the goal.

  1. The power of teamwork.  Hockey is not an individual sport it requires every member of the team to play their part to win.  It also requires everyone to be at their best.  Open communication and chemistry are an essential part of teamwork.
We all have roles in our organizations but it is the power of teamwork that makes our endeavors successful.  It takes everyone working together on a common goal to be successful in Lean.

  1. The value of hard work and sacrifice.  The Bruins have undoubtedly worked very hard and made sacrifices along the way to get to where they are.  But this makes winning so much sweeter in the end. 
Lean takes lots of hard work as well but it makes wins you get much more pleasurable.  It is this hard work that creates customer value and makes your organization competitive in the market place.


I hope you can learn from these lessons as I have and find a way to incorporate them in your life and your work. Keep learning.

Congratulations Boston Bruins for winning the Stanley Cup.


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Wednesday, June 15, 2011

8 Things to Avoid to Make Your Kaizen More Successful Replayed

If you missed the webinar, 8 Things to Avoid to Make Your Kaizen More Successful, that Jeff Hajek and I did on Friday, June 3, 2011 you can view the replay now.  In this webinar we talk about the use of kaizens in your organization and share 8 mistakes to avoid to make your kaizen effective. This is based on years of experience performing, leading, and teaching kaizens.





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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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