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Tuesday, November 20, 2012

Daily Lean Tips Edition #39

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 #571 – Identify and remove root causes to permanently fix problems.

The root cause is the fundamental, underlying reason for a problem. The root cause is what causes a problem to happen repeatedly. If you do not identify the root cause, you are just putting a bandage on the problem. It will probably happen again. When you remove the cause, you have fixed it permanently.

Lean Tip #572 – Monitor your improvement results to see your target was achieved, not just whether there was a change.

If you didn’t accomplish what you had hoped, three reasons are possible. Your plan may have been poorly executed. You may have developed a poor solution. Or, you may have attacked the wrong cause. Try again if necessary.

Lean Tip #573 – Data collection and analysis tools are critical for monitoring improvement.

Did you accomplish your objectives? When you review the results, ask whether your targets have been achieved. Process analysis and monitoring tools are important for determining whether the overall project goals were met.

Lean Tip #574 – If your solution worked, standardize to lock in the improvement.

Introduce the solution to everyone affected. Make sure whatever changes have been made become routine. Prevent any slipping back into the same old problems. Consider all elements of the new process: people methods, machines, materials, and measurements. Have they all been standardized?

Lean Tip #575- There are several aspects to standardizing an improvement process.

First, “new and improved” won’t do much good unless it is used consistently throughout the organization. Plan to expand your test solution to everywhere it appears. Second, everyone involved in the new proves must know what to do. Formal and informal training is essential to spread a new process throughout the organization. Third, it is critical to identify who owns the improved process, including responsibility for continued tracking of measurement.

Lean Tip #576 - Enable Employees by Setting Clear Goals.

People make more progress when leaders are clear about the link between what they do and what matters to the organization. And successful teams are those that have clear goals, and where people know how their work affects those goals. Help your people gain line of- sight visibility from their work to the team’s goals.

Lean Tip #577 – Help employees break projects, goals, and work assignments into small victories.

Small victories tap into motivation. Achieving is fueled by making small amounts of progress, such as accomplishing a task or solving a problem. Help those that work with you jump into an achievement cycle and experience the benefits and rewards of moving through all five steps.

Lean Tip #578 - Teach people how to manage time and energy wisely.

Coach employees to fully engage in the task at hand, focus on the important rather than the urgent, avoid distractions, and create balance and renewal in the achievement of the goal. Help them learn to say no to urgent requests or terrific ideas that aren’t aligned with the important work of the team.

Lean Tip #579 – Enable employees by committing resources and removing roadblocks.

Enable people to move forward in their work by committing appropriate resources, removing obstacles, helping them work across boundaries, and aligning processes, structure, and systems.

Lean Tip #580 - Help employees engage others.

Encourage those you work with to reach out and engage others with similar goals. Remind them that goals can be created independently, but achieving them almost always requires help and support from others.

Lean Tip #581 - Employees need to be able to trust their managers and company leadership.

Clear communication is a key element of trust. To build trust, monitor how and what you communicate to people around you. Be clear and direct. Manage expectations. Be truthful and as transparent as possible to avoid guesses and assumptions and to prevent rumors and unfounded fears from spreading. In organizations under stress, sometimes it is difficult for leadership to be completely forthcoming. Few people expect everything to be perfect all the time, but uncertainty breeds discontent. Tell employees as much as possible as early as possible, even if it is bad news.

Lean Tip #582 – Leaders Need To Create Connections For Employees

People want to have meaning in all aspects of their lives. If they do not feel the importance of what they do, they disconnect. Therefore, it is important to highlight the connections between things and people. Help employees see the “big picture” of how their role and objectives fit into the organization’s objectives. Encourage others to look at how their actions and performance affect others.

Lean Tip #583 – If You Want Engaged Employees Motivate Them with Appreciation.

Recognition is an important part of motivation and engagement, and it can be as simple as genuine appreciation. Praise where warranted and give credit where credit is due. The best recognition is immediate, specific, and personal. Let the person know specifically what you appreciate about her or what she did, and do so in a way that the individual will appreciate (some people like public praise, others prefer a one-to-one chat).

Lean Tip #584 – Strong Leaders Motivate Others to Be the Best They Can Be

Motivation is our desire or willingness to do something. An organization where people are willing and able to work toward a common goal is stronger than one where people are badgered or threatened or generally reluctant. Leaders with higher degrees of emotional intelligence tend to get better results through inspiration, persuasion, empathy, and integrity. Use your listening, persuasion, and influence skills to inspire and motivate people to work toward a common goal.

Lean Tip #585 - Support Your Employees by Developing Their Growth

There is nothing more demotivating than feeling you’re in a dead-end job. Talk to employees about what direction they’d like to see their career path take, and help them identify opportunities for personal and professional development that will help them achieve those goals. Share with them ideas they can use for their own career management within the organization. Move past any fear you may have of your employees leaving – by caring about their growth and aspirations, you will probably get a more productive, loyal, and longer-term team member than if you don’t have these conversations.


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Monday, November 19, 2012

Facts Speak For Themselves


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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Friday, November 16, 2012

Lean Quote: Four Attributes of an Effective Performance Measurement System

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.

"What gets measured gets done. Make sure you are measuring the right things!" — Peter Drucker

An effective measurement system is one of the most powerful tools for change. In a perfect world, a measurement system will actively promote performance improvement by measuring what matters; providing corrective feedback and positive reinforcement to enthusiastic people who enjoy being measured and take improvement on as a challenge.

An effective performance measurement system should have the following four attributes:

First key of a successful measurement system is Context. Effective measurement can only occur in a positive, supportive context. This is the culture that surrounds the measurement - informational or punishment, process not person. The attitude of the boss. An unfavorable measure is an opportunity not a threat. We want to surface issues, not suppress them.

The second key for a successful measurement system is Focus. Measure the right thing. Be aware of measuring too much. Derive many of the measures from participative policy deployment, not sucked out of the air.

The third key for a successful measurement system is Integration. There must be an integrated system for measurement. Maybe a balanced scorecard or policy deployment, although better in a Lean context would create flow, maintain flow, and organize flow. In any case measures need to be aligned, balanced, and adaptive.

The fourth key for a successful measurement system is Interactivity. Measures need to be acted on in real time. Two-way interaction. Actually setting up the measures is only a small part - how they are used and reviewed is at least as important. Perhaps a daily meeting around the communications board. This is social process, not a technical process.

Good systems need good people. There is no sense in examining a process unless at the same time you examine the people who govern the process. Improvement does not take place on paper. Improvement happens when people employ enthusiasm, dedication, commitment, leadership and morale in their daily routine. A good system on paper is a healthy beginning but if you want results you need to follow up a paper system with a people system.


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Wednesday, November 14, 2012

The Successes of Lean Manufacturing and Six Sigma: A Case Study


Those who deal with Six Sigma and Lean Manufacturing on a frequent basis will be fully aware of the benefits they can have for businesses; dramatic improvements in quality and service, improved customer satisfaction and improved reliability, are just to name a few. 

But, it’s rare that individuals looking to learn more about the philosophy of these techniques actually get to hear about real life examples, of how these processes have contributed to the rising success of a company. 

In construction and engineering, the process of Six Sigma and Lean Manufacturing is key. Its adoption allows for maximum durability and quality for many hardwearing operative products that require use on a day-to-day basis, under all weather conditions. It’s because of this that many engineering companies are now looking to adopt these processes in their production strategies. 

But, it’s not just the consumer that benefits from these processes. As this case study featuring the manufacturing company Midlake Products shows, the pros of Lean Manufacturing and Six Sigma can contribute to significant growth of a company itself. If you’re looking to find out more about how the processes can contribute to your business, here’s how it worked for Midlake Products: 

Quality and Reputation 
Midlake Products and Manufacturing is a privately held, family owned business, which was established in 1987. With custom hinges, metal fabrications and metal finishing acting as the main foundations of the business, the company has gone from strength-to-strength and now services all trades from the marine industry to self-service industries. 

Midlake Products continue to practice and embrace the philosophy for Six Sigma and Lean Manufacturing, and it’s these that they believe have been the key contributors to the success of their products. 

By investing in Six Sigma technology that seeks to improve the quality of process outputs by identifying and removing defects, Midlake Products minimize any variability in their manufacturing. It’s through this that Midlake can continually meet their important quality policy, which strives to provide products to their customers, which meet or exceed their expectations. The further use of quality management methods and tools, including a special infrastructure of people consisting of “Black Belt” or “Green Belt” experts, means that Midlake’s customers always benefit from outstanding quality and reliability products. 

And as previously stated, it’s not just Midlake’s customers that benefit from these features. By striving to provide the highest quality products possible, Midlake has earned itself a positive reputation and superior competitive position within the industry as a result. As any business owner will know, these traits often result in increased sales and profits, often brought by both current and prospective customer loyalty. 

Financial Benefits 
All Six Sigma and Lean Manufacturing projects carried out within an organization consist of a defined sequence of steps and quantified financial targets, in order to help reduce costs or increase profits for the company as a whole. It’s these that equate to substantial financial benefits for the company that adopts the techniques into their manufacturing strategies. 

Lean Manufacturing in particular, considers the expenditure of resources by working from the perspective of the customer who consumes the product, and the company that creates it. The final product is value for both parties; value relating to the price the customer wants to pay for a high quality product, and value of product costs for the company. 

In the example of Midlake Products, their journey to effectively implement these financial targets by lowering costs for themselves whilst maintaining quality for the consumer, is ongoing - and one that has significantly contributed to their success as a result.

About the Author:
This article was written by Kathryn Thompson, an experienced freelance writer. Kathryn specializes in providing real-life business examples of the benefits of Lean Manufacturing and Six Sigma, such as in the case of Midlake Products and Manufacturing. Midlake Products and Manufacturing is a privately held, family owned business, which was established in 1987. With custom hinges, metal fabrications and metal finishing acting as the main foundations of the business, the company has gone from strength-to-strength and now services all trades from the marine industry to self-service industries. 


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Tuesday, November 13, 2012

Get Involved - 3rd Annual World Quality Month



Join the Global Quality Community in celebrating World Quality Month in November 2012! Now in its third year, World Quality Month provides a platform for acknowledging the efforts and accomplishments of the Global Quality Community. This is a time to celebrate—a time to showcase the advancements and valuable quality contributions in businesses, communities, and institutions.

World Quality Month is an annual celebration of quality and its impact in the world. Through the joint efforts of ASQ, its many World Partner organizations, leaders and stakeholders in the Global Quality Community, the inaugural World Quality Month began in November 2010. World Quality Month was established both to reignite attention once generated in the 1980s by National Quality Month in the U.S. and to create a united, global forum for the organizations that have celebrated World Quality Days in November to come together and raise their voices for quality. 


Visit worldqualitymonth.org often to learn about quality tools and techniques, heroes, the stories of quality in practice every day, and World Quality Month events. Celebrate World Quality Month 2012 with the Global Quality Community. 

So in November get involved. Raise your voice for quality. Make a point of it. I bet you’ll enjoy it. And when December 1 rolls around, you don’t have to stop. Speaking up for the importance of quality is our daily responsibility. The biggest barrier quality faces is making people understand that excellence just doesn't happen. Excellence isn't good intent. Through quality, excellence is available to everyone.

Together—through our collective passion for the community—we will raise the voice of quality worldwide.


I’m part of the ASQ Influential Voices program. While I receive an honorarium from ASQ for my commitment, the thoughts and opinions expressed on my blog are my own.

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Monday, November 12, 2012

The Outstanding Organization is Outstanding

What’s holding back your organization? Are people still fighting fires, missing targets, producing defects, and doubting direction? Why haven’t you been able to sustain your gains? 

After two decades in the trenches of helping companies design and build better, more efficient operations, Karen Martin has pinpointed why performance improvement programs often fail: chaos, the sneaky but powerful force that frustrates customers, keeps business leaders awake at night, and saps company morale. 

Karen says that chaos in the organization is caused by: 

Lack of clarity – ambiguity abounds in purpose, roles and responsibilities, decision making, and communication 
Lack of focus – changing priorities, trying to solve too many problems at once, and distraction 
Lack of discipline – mastery requires deliberate practice, PDSA improvement cycle 
Lack of engagement – energized and connected with a purpose, employee development 

Chaos is not something we have to live with. Karen says we need to improve how we improve. The Outstanding Organization provides a means for combating chaos by creating the organizational conditions that will allow your improvement efforts to return greater gains. Karen’s system focuses on four key behaviors for operational excellence—Clarity, Focus, Discipline, Engagement—that, once they become habit, open the door to sustainable growth and profit. 

The book's central idea is that the key to removing the friction and chaos found in the daily operations of most organization is to (1) pursue clarity in internal communications, (2) focus on a small number of topics to reduce the time members spend switching between projects and give teams a chance to finish what they start, (3) have the discipline to keep practicing what makes it function better, and (4) engage members so that they identify their own goals with those of the organization. 

Karen's proven, practical, and surprisingly straightforward wisdom is easily digestible and understood. Her expertise is apparent with many great real-world examples of different organizations that she has worked with over the years. In addition to her own knowledge, Karen polled scores of experts and talked to many thought leaders to test her thinking, strengthening the value of the book. She has a tremendous knowledge of previous Lean literature and sites a large number of them throughout the book. 

The Outstanding Organization is a quick read but packed with a number of tools and techniques for solving problems that take longer to fully appreciate. This book would be good for a study group, creating great discussion that can lead to immediate results.  

Unfortunately, there is a lack of visuals, diagrams, pictures to support the teaching in the book. As a visual learner I would have liked some visuals to reinforce the learning. 

The Outstanding Organization will make any process initiative work better and stick longer. Plus, it will help produce demonstrable results. Karen shows us how an outstanding “Lean” organization can free up employees to do their best work. 

I recommend you add this book to your Lean library of knowledge. I am confident you will find value in this book well into the future.

Friday, November 9, 2012

Lean Quote: A Lack of A Problem Solving Process Means More Problems

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.

"Problems breed problems, and the lack of a disciplined method of openly attacking them breeds more problems." — Philip Crosby

We are all faced with problems to solve in our workday. There are many problem-solving methods, and the six-step method is just one of them. The problem for most people is that they do not use one process to solve problems and issues or to make decisions. Another problem is that people are not consistent in how they solve problems. They do not find something that works and then do it the same way over and over to be successful. 

The Six-Step Problem-Solving Process is described below: 

Step 1: Identify The Problem 
  • Select the problem to be analyzed 
  • Clearly define the problem and establish a precise problem statement 
  • Set a measurable goal for the problem solving effort 
  • Establish a process for coordinating with and gaining approval of leadership 

Step 2: Analyze The Problem 
  • Identify the processes that impact the problem and select one 
  • List the steps in the process as it currently exists 
  • Map the Process 
  • Validate the map of the process Identify potential cause of the problem 
  • Collect and analyze data related to the problem 
  • Verify or revise the original problem statement Identify root causes of the problem 
  • Collect additional data if needed to verify root causes 

Step 3: Develop The Solutions 
  • Establish criteria for selecting a solution 
  • Generate potential solutions that will address the root causes of the problem
  • Select a solution 
  • Gain approval and supporter the chosen solution 
  • Plan the solution 

Step 4: Implement A Solution 
  • Implement the chosen solution on a trial or pilot basis 
  • If the Problem Solving Process is being used in conjunction with the Continuous Improvement Process, return to Step 6 of the Continuous Improvement Process 
  • If the Problem Solving Process is being used as a standalone, continue to Step 5 

Step 5: Evaluate The Results 
  • Gather data on the solution 
  • Analyze the data on the solution 
  • Archive the desired results?
    • If YES, go to Step 6. 
    • If NO, go back to Step 1. 

Step 6: Standardize The Solution (and Capitalize on New Opportunities) 
  • Identify systemic changes and training needs for full implementation 
  • Adopt the solution
  • Plan ongoing monitoring of the solution
  • Continue to look for incremental improvements to refine the solution 
  • Look for another improvement opportunity 

The Six-Step Problem-Solving Process is an easy approach to dealing with issues and problems that you face. It is a systematic way to approach a problem with clearly defined steps so that an individual or team doesn’t get bogged down in, “WHAT DO WE DO NEXT?”

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