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Wednesday, April 24, 2013

Book Review: The Lean Practitioner’s Handbook




Any time you are trying to learn something new or you need to jog your memory your will find a reference guide helpful. Mark Eaton, as consultant, author and lean practitioner himself, authored a practical reference guide that will be useful on a day-to-day basis. TheLean Practitioner’s Handbook bridges the gap between the tools and the concepts of Lean and the practical use of the tools.

Eaton discusses key areas, such as: aspects of a Lean Program; scoping a program; value stream mapping; 2P and 3P events; rapid improvement events; managing for daily improvement; engaging the team; spotting problems and communicating progress.

This book covers a wide variety of tools and concepts and explains how to apply them in practice.

List of Chapters
1 Planning for Lean
2 Key Lean concepts
3 Scoping projects
4 Value stream mapping events
5 2P/3P events
6 Rapid improvement events (RIE)
7 Managing for daily improvement (MDI)
8 Leader standard work (LSW)
9 Strategic planning
10 Engaging the team
11 Ensuring success
12 Communications and celebrations
13 Key tools and concepts

The book also includes a wide range of templates and checklists to help you prepare for and deliver Lean events and activities and embed the changes that arrive. These checklists and templates are also available online by registering at www.koganpage.com/Lean.

It is structured from the standpoint of conducting a lean event or project focused on one area. As a result this book is well suited for those in frontline to middle management roles, individuals we would refer to as practitioners.

Each chapter starts with a series of questions Eaton intends on answering for the reader.  The chapters conclude with closing thoughts to summarize the learning of the chapter. There is a useful glossary of terms and index to help you locate specific terms.

Eaton has put his own experience into this book with advice and techniques for leader standard work, ensuring success and communication that I found particularly useful. However, he misses an important concept in Lean centered on “respect for people.”

As a reference guide The Lean Practitioner’s Handbook offers a snapshot summary of key tools and Lean concepts. It a practical, easily accessible resource for anyone in implementing Lean.

Disclosure: The publisher sent me a copy of this book for my review.













Tuesday, April 23, 2013

Daily Lean Tips Edition #46

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 #676 - Find the lesson or opportunity within the problem.
There is almost always a good side of a problem. Perhaps it alerts us to a great way to improve our business. Or teaches us how our lives perhaps aren’t as bad as we thought. Finding this more positive part of the problem reduces its negative emotional impact and you may even start to see the situation as a great opportunity for you. When you are faced with a problem ask yourself: How can I use this? What is the good thing about this? What can I learn from this? What hidden opportunity can I find within this problem?

Lean Tip #677 - Use the 80/20 rule when problem solving.
Use 80 percent of your time to find solutions and only 20 percent to complain, worry and whine. It might not always be easy but focusing your energy, time and thoughts in this way is much more beneficial to you and others than doing the opposite.

Lean Tip #678 - Break down the problem into smaller pieces.
Completing a task or solving a problem can seem overwhelming and impossible if you take it all in at once. To decrease anxiety and think more clearly try to break the problem down. Try to identify the different things and people it consists of. Then figure out one practical solution you can take for each of those pieces. Try those solutions. They may not solve the whole problem immediately. But they might solve a few pieces of it. And then you can keep trying other solutions for the rest of the pieces until there are none left.

Lean Tip #679 - Gather some good knowledge about the problem you are solving.
Information about your problem can often decrease that uncertain anxiety and fear we face when we are challenged with something. Knowledge wisps away the clouds of fear around a problem. And we often find that the problem might not be as bad as we thought.

Lean Tip #680 - Focus on what you can change – the future.
Discussion about what happened in the past and providing examples may be necessary for understanding, but it is not to convince the other person about your rightness or to defend yourself. Hindsight is useful in reflection and learning but not solving the problem.  Focus on what you can change in the future to prevent the problem.

Lean Tip #681 - Ask For Employee Input.
Eliciting experienced viewpoints from various levels within your organization helps you plan effectively. For example, practical consequences that are immediately apparent to employees on the ground might not occur to management.

Lean Tip #682 - Delegate Responsibilities So Employees Are Empowered.
Distributing power gives everyone a stake in the success of a change initiative. Otherwise, employees might feel plowed under and helpless, which could lower worker morale and jeopardize the initiative.

Lean Tip #683 - Acknowledge Your Staff On Their Achievements.
A pat on the back, some words of praise, and giving a note of credit to the employee / staff member at personal level with some form of broad publicity can motivate the staff a lot. Make it a point to mention the staff’s outstanding achievements in official newsletters or organization’s journal. Not only acknowledge the employee with highest contribution, but also acknowledge the employee who meets and over exceeds the targets.

Lean Tip #684 - Give The Employees Learning Opportunities.
Employees should consistently learn new skills on the job. It has been well said by someone that with people hopping jobs more often than required and organizations no longer giving job security to employees, the young blood employees specifically realize that continuing learning is the best way to remain employable. Opportunities should be given to the employees to develop their skills and competencies and to make best use of their skills. Link the staff goals with the organizational goals.

Lean Tip #685 - Set An Example For Your Employees.
Be a role model for your staff. The staff would learn from what you do and not from what you say / claim. The way you interact with your customers and how do you react later after the interaction is over have an impact upon the staff. Employees more closely observe your non-verbal communication (gestures, body language). Being unpunctual, wasting the organization’s capital, mismanaging organization’s physical equipments, asking the staff to do your personal work, etc. all have a negative impact on the staff. Try setting an example for your staff to follow.

Lean Tip #686 - People change for something better rather than to avoid something worse
Threats are fine for determining behavior, but they just don't create real change. Here are two approaches that don't work: "You had better do this, or it's your job." "If we can't figure out how to do this, we'll be out of business." Instead, realize that lasting change comes from within — from the heart, from the spirit. To create lasting organizational change, you must develop a vision of a better work life — a vision that people can really believe in.

Lean Tip #687 - Processes are really just ideas
Most change efforts require changes to organizational processes, and we have some great tools for representing processes. The tools are too good, though — we sometimes forget that processes have no physical manifestation. Processes are just ideas, and ideas exist only in our minds. So if a process is to change, what is in people's minds must change — their ideas about the processes, and how they, as people, relate to the processes and to each other.

Lean Tip #688 - Change your change process
If you get better at making changes in your organization, and if you keep at it, your organization will soon be a top performer. Why? So few organizations succeed at making lasting change, that it doesn't really take much to become a top performer. It looks like it takes a lot, because lasting change is so hard to do. To make change easier to do, invest first in getting better at changing things.

Lean Tip #689 – Space your changes to avoid collisions
If your organization is just beginning to move out of the Chaos of one change effort, and you zap it with a new Foreign Element from another change effort, you'll slow progress on the first change effort. Space things out to give the organization time to integrate and Practice previous changes.

Lean Tip #690 - Expect change to take longer than you expect
Recognize that in your own mind, you've already made the change. You've thought it through, and you know where you want things to go. But nobody else has — well, hardly anybody. Getting everyone to move to where they will want to go will take time. And we always underestimate how long it takes. Always.


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Monday, April 22, 2013

Lean Eliminates DOWNTIME, Green adds FEWER


Today is Earth Day 2013 whose theme is the Face of Climate Change.  I am not an expert in this topic and nor I am going to talk about it here.  However, in celebration of the environment today I thought I would share some thoughts on the use of Lean and Green together for the better.

I have talked about how Lean eliminates downtime before.  DOWNTIME is a acronym I use to remember and explain the eight wastes of processes.

Defects
Over-production
Waiting
Non-utilized Resources/Talent
Transportation
Inventory
Motion
Excess Processing

By focusing on reducing or eliminating the Eight Wastes associated with DOWNTIME we can shorten the lead time to the customer. This will result in lower costs, higher capacity for more demand, and increased customer satisfaction which are all desirable to grow your business profitably.

Green is a synergistic concept to Lean where the focus is on eliminating environmental waste.  WASTE is another acronym I shared to explain and remember the 5 key environmental wastes.   It could also be said that Green adds FEWER:

Full use of raw material
Energy efficiency
Water conservation
Elimination of toxic/hazard material
Reduction
       -Packaging
       -Emissions
       -Waste

The most obvious benefits of Green and Lean are cost savings which are synergistically coupled with value creation opportunities. Cost savings may include energy savings, productivity savings, and savings from improved utilization of materials. Value creation opportunities may include innovations that involve creation of new products out of waste materials and finding ways, in service delivery processes, to enhance customer’s experience.

Lean eliminates DOWNTIME by reducing those wastes.  Green adds FEWER by reducing WASTE.  The key to being successful  at Lean and Green is to focus on FEWER WASTE causing DOWNTIME.

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Friday, April 19, 2013

Lean Quote: Today Should Be Better Than Yesterday, And Tomorrow Should Be Better Than Today

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.

"Yesterday’s Home Runs Don’t Win Today’s Games." — Babe Ruth


This Babe Ruth quote is a great reminder of how you shouldn't coast too much after achieving a goal. Unfortunately, we see all too often those companies who finally reach #1 to only lose their way.

Complacency can and will compromise the performance of your organization. Everyone can become complacent in their particular environment, and there are different levels of complacency. At higher management positions, complacency may be more latent. At the line personnel “trigger pullers” level, however, complacency can have catastrophic results.

When it comes to complacency with regard to Lean it is often the result of a “We are Lean” mindset. This leads to a reduction in awareness/focus and leads to a false sense of security. For Lean to work effectively, the organization must be constantly focused on continuous improvement and best practice procedures for providing value. What sets an effective Lean system apart from simply reducing waste is engraining continuous improvement thinking into daily practice. Lean is not about a destination but rather journey.

Perhaps being second is better than first. It is unlikely that the first attempt at anything will be the best attempt ever by anyone. This would be like the very first Olympic 100 meter gold medalist setting a world record that is never beaten. The first product proves that something works but it is improbable that it represents the best solution. Better solutions will follow, all of which have a chance at being more popular than the original.

Today should be better than yesterday, and tomorrow should be better than today. This is the essence of continuous improvement. Coasting and complacency is a recipe for failure. The competition is always looking to take your lunch if you let them.

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Wednesday, April 17, 2013

Book Review: Perfecting Patient Journeys

Healthcare is undergoing many changes these days which has long been overdue for those of us who have been patients.  Lean thinking has been spreading globally for decades in product and service businesses. In the last few years this value stream improvement methodology has been gaining support in health care.  Now there is a step by step guide for visualizing the patient experience and improving the flow of value with Perfecting Patient Journeys.




Published by the Lean Enterprise Institute (LEI) Perfecting Patient Journeys is a guide for leaders of healthcare organizations who want to implement lean thinking. Readers will learn how to identify and select a problem, define a project scope, and create a shared understanding of what's occurring in the value stream. Readers will also learn to develop a shared vision of an improved future, and how to work together to make that vision a reality.

The authors describe and advocate a value-stream approach to improvement bringing together both scientific and cultural components needed to transform Lean Healthcare.

The workbook comprises of 8 chapters which constitutes the steps of the improvement cycle:
  • Team-based problem solving and learning for continuous improvement
  • Scoping your improvement project
  • Value-stream mapping – current state
  • Future-state mapping
  • Measuring the future state and planning for change
  • Establishing project management
  • Keeping your improvement project on track
  • Moving forward- from projects and events to consistent practice
                            
The basis of the workbook was a field guide developed for support of training during collaborative sessions in a project with MHA Keystone Center for Patient Safety & Quality. Throughout the book the authors, who worked on the project, utilize their case study of St. Luke’s Hospital initiative to improve the performance of their emergency department as an example.  They include details of improvement from St. Luke’s that makes it easy to follow and implement this improvement approach.

While this workbook is intended for practitioners with direct interaction with patients it also helps senior leadership understand and support system level improvements. Written is a clear manner without excessive Lean jargon or terminology, this book presents the value-stream improvement approach, which simultaneously blends the ability to change structure and process while changing culture.

Perfecting Patient Journeys follows the style as other LEI workbooks but has a different look. This workbook doesn’t have the typical spiral binding of the other workbooks as it a hard cover book. Likely this was done to better market the target audience of healthcare professionals. Personally I prefer the spiral bound style for its convenience in the gemba or at team meetings.   

While the audience for this book is clearly healthcare workers it has easy application for any service process. This guide presents a method to sort through problems, establish priorities, and focus on solving the right problems with teamwork which is applicable in all processes. Lean practitioners and those alike interested in learning an improvement methodology based on eliminating waste within a value stream with teamwork will find this book a helpful reference guide.


Disclosure: My friends at LEI sent me a copy of Perfecting Patient Journeys for my review.














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Tuesday, April 16, 2013

The Benefits and Impact of Global Quality Award Programs


In this month’s ASQ post by Paul Borawski he asks the Influential Voices to discuss the impact of Global Quality Programs.
Do you live in a country with a national quality program?  Is it serving to create role models for others to emulate?  Is the national program growing in visibility and perceived value and creating capacity for national excellence?
If you search Google for “Quality Award Programs” you may be surprised by the number of programs.  I certainly didn’t realize how many programs focus on quality. I suppose this speaks well for the emphasis on quality products and services.

I think we can all agree that a Quality Award for the sake of an award is not beneficial.
However, many organizations around the world are turning to quality award programs for more than just the recognition such programs offered. Companies realize that the awards also offer models and tools for implementing a quality strategy, benchmarking best practices, performing self-assessments and, ultimately, achieving improvements.

Many organizations are effectively using quality award programs to advance their journey to attain quality leadership. Here are some guidelines for effectively using quality award programs:
  1. Do it to drive excellence, not to win the award.
Many organizations have gotten off track by making the award the ultimate goal. This can result in gaming the system to look better than you actually are. In the meantime, the organizations lose sight of their true purpose of providing value adding products and services to customers.
  1. Use a long term focus.
Once and done is almost always a wasted effort. It is not enough to reach award winning levels of quality leadership. The real goal is to sustain quality leadership performance. Most quality award winning organizations will self-assess and apply multiple times over several years. They recognize that achieving and sustaining quality leadership is a journey.
  1. Use the feedback.
It is always amazing when an organization goes all the way through the process of compiling and submitting an application and then ignores the feedback they receive from the evaluation process. This is the gold nugget. This can be some of the best advice an organization will ever receive from a team of industry leading experts. Smart organizations use this feedback as a major component of strategic and business planning to identify areas of focus.
  1. Focus on process.
The results will follow. Most quality award criteria seek information related to business processes and business results. The key to success is to understand how processes drive results and focus on improving the processes so better results can be attained.
  1. Develop internal expertise.
The awards cycle will provide valuable feedback to the organization, but it can take a long time to get the information. Organizations which develop internal expertise can strengthen their own assessment processes. This enables the organization to get regular and timely information for improving processes and performance

Quality awards are not indicators of previous or future performance. They are a one-time snap shot. If your organization is seeking quality improvement, then a Quality Award can play a significant part in helping you along the journey. Quality awards provide an excellent source for monitoring progress and identifying opportunities for improvement.

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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