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Wednesday, October 14, 2015

Daily Lean Tips Edition #85 (1276-1290)

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 #1276 - Allow Others to Shine
Be a leader with the intention of letting the people around you showcase their abilities. Allow them to give advice and suggest ideas by posing questions that encourage interaction. Being a leader doesn’t mean being a know-it-all; keep learning from your team.
Give your team some credit and praise in front of others. Some people may find this uncomfortable, but I think that letting other people know how well your teammate is doing can really boost their self-confidence and help them maximize their performance!

Lean Tip #1277 - Find the Balance Between Aggressive and Realistic Goals
Create a culture of performance by setting aggressive goals and holding your employees accountable for regularly reporting on their progress. However, the goals can't be so aggressive that your employees quickly fall behind and feel like they can never realistically achieve them. Otherwise, they will quit stretching to reach the goals. That means that you have to regularly re-evaluate the goals (at least on a quarterly basis) to decide whether they need to be scaled down or scaled up.

Lean Tip #1278 - Trust Your People — And Let Them Know It
Knowledge workers typically have jobs that require creative solutions and decision-making. They need to stay sharp mentally to achieve top performance. The onus is on management to create an atmosphere that fosters and encourages that kind of creativity. One of the best things you can do is to let your employees know that you trust them and that you have faith in their ability to do the job, solve the problem, and/or meet the deadline.

Lean Tip #1279 - Avoid Blame (a.k.a. Throwing People Under the Bus)
In any business, there are going to be times when you fail, and there will be things that simply don't pan out the way you had hoped. Do a post-mortem (even if it's informal) to figure out what went wrong and learn from it. If there were egregious errors made by individuals, deal with them privately. If necessary, let the person know your expectations for how this should be handled in the future. Don't publicly blame individuals — either directly or indirectly — in meetings or team e-mails. If you do, you risk creating an atmosphere in which people are so afraid to make mistakes that they don't spend enough time doing the proactive and creative work necessary to avoid future problems — or more important, to drive new innovations.

Lean Tip #1280 - Don't Provide All the Answers — Make Your Employees Think
You are the manager. You are the leader. That does not mean that you have a monopoly on all of the good ideas. If your employees are hesitant to make decisions without asking your opinion first, you haven't properly empowered them. If your employees aren't making enough of their own decisions, you should change your tactics. When they present you with information and ask what to do about a situation, push the ball back into their court and ask them, "What do you think?" They might be surprised at first, but after you do that several times, they'll start thinking it through before they come to you so that they're fully prepared to discuss the matter and make a recommendation. That's a good thing, because they're usually closer to the customer and more familiar with the details of the work. You need their opinions. And you need them to make some of their own decisions.

Lean Tip #1281 - Build Consensus by Letting People Know "Why"
One of your key responsibilities in management is communicating about new initiatives and strategy changes. The worst thing you can do is surprise your staff members with a fully formed idea about a new way to do something that will drastically alter their day-to-day work. When you spring it on them, people will naturally be defensive and skeptical. Whenever possible, give people an informal heads-up that a change is coming and let them know some of the reasoning involved. They will be glad you kept them in the loop. An even better course of action is to have a brainstorming session with your team when you are still formulating a new idea or strategy change, so you can gather their ideas and feedback. 

Lean Tip #1282 - A Team Leader Should Lead by Example. 
They should do this by not being afraid to jump into the ‘trenches’ and do some of the sales work themself and by negotiating resources for the team. They should also encourage team members to take risks and support them when they do. Being a hands on manager will inspire and motivate the team to achieve greater things.

Lean Tip #1283 - Teach Adaptability to Your Team. 
The effective team manager should teach adaptability and flexibility to all of his team members. Being able to change focus and have adaptability in learning and sharing information allows for better communication, a greater sense of empowerment among staff and a faster exchange of information.

Lean Tip #1284 - Bring Positivity into the Workplace
Leaders have a quality of motivation to them, whether it is contagious from their work ethic or it could possibly be that they are visionaries and people want to follow them, but one characteristic of a great leader is their positive, upbeat attitude. Bringing positiveness into the team is a crucial piece in effectively leading a team. It allows people to have something to grab onto when the going gets tough, which we all know it will. 

Lean Tip #1285 - Establish an Impeccable Standard of Excellence.
Set high expectations at the outset and raise the bar on any crucial factors. The best way to establish a standard is by modeling the expected behavior yourself. Showcase excellence. When your actions have the potential to affect everyone around you and the bottom line, don't dabble in mediocrity. Reflecting excellence is critical to exercising effective leadership. This is ground zero for establishing influence.

Lean Tip # 1286 - During Business Changes, Engage Employees by Understanding Their Needs.
Change happens within every company, and if handled poorly, it can result in employee uncertainty and turnover. Prevent that situation by understanding what they need to re-engage. With each new announced change, it’s natural for employees to ask: “What’s in this for me?” But if you effectively hook people’s hearts, you reduce employee questioning. Good leaders understand that with every significant change, employees need to be re-enrolled in their work. Employees need to believe their best days are ahead of them or they will check out without you knowing it.

Lean Tip #1287 - To Step Out of Your Comfort Zone, Determine the Best and Worst Outcomes
To evaluate risks and rewards, try to determine what the worst-case scenario would look like, whether the payoff is worth that risk, and how you could prevent it from happening. Consider the best-case scenario as well: How will you recognize success? What will you do next? This helps you prepare for contingencies.

Lean Tip #1288 - For Team-building Activities, Encourage Collaboration, Not Competition
If a team-building activity has a contest element, some employees will become so focused on "winning" that they may fail to learn anything from the experience. Instead, choose an activity that encourages your staff to work together to solve a problem.

Lean Tip #1289 - See Mistakes as Opportunities that Set You Up For Progress
Embrace mistakes as opportunities to grow. In today’s business climate, people are making split-second decisions. That presents the likelihood for mistakes. But keep in mind that if you’re not making mistakes, you’re not taking any risks. And that could mean you’re not making progress. Managers have a specific role in dealing with staff mistakes. You want your staff to make as few mistakes as possible. But workers do need to know when they make mistakes, so that they can learn and grow in the workplace.

Lean Tip #1290 - Connect With Employees by Sharing Your Vision and Goals
Provide a clear and compelling vision with goals to employees and job candidates. This also includes investors and customers, so everyone can see what they need to do, get excited about the opportunity, and attract top talent to work with and alongside your team.


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Monday, October 12, 2015

Change Brings Opportunity


Change can be a difficult thing. People commonly resist change and I am no different however change is inevitable. It can be stressful especially when it is unknown and uncertain.

However, change is necessary for growth. While it may be very comfortable to stay in a place of familiarity, we will never grow into the person we would like to be if we are unwilling to move beyond what is comfortable.  Many people become complacent because the common notion is that change is bad. This couldn’t be further from the truth. Change can be very healthy and liberating. How we respond to change is a function of our mindset. Change your mind, change your outlook.

Change takes courage and commitment. Courage means trusting yourself to overcome your fears and doing what you are afraid to do. Courage increases conviction and inspires others to confront their fears.

After 4 years in a quality management role change is coming personally.  My telecom company is closing my factory and outsourcing manufacturing so I am moving on. I am excited and anxious to be starting a Lean Manufacturing role in well-known company.

This change brings new opportunities, new people, and a new perspective. It is a chance to rejuvenate my passion and purpose. This is an exciting opportunity to get back on the factory floor helping others improve their work to keep manufacturing in the US. After a period of time working from the customer value view point you can see the impact of our actions directly.

There won’t be many changes on the blog as a result. I will still continue to talk about leadership, continuous improvement, and quality. They remain vital aspects of all businesses and frankly a common source of opportunity.


Change is good. It leads to opportunities. Those opportunities represent progress. Keep moving forward.

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Friday, October 9, 2015

Lean Quote: Success as Leader is All About Growing Others

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.

"Before you are a leader, success is all about growing yourself. When you become a leader, success is all about growing others.— Jack Welch

One of the most important qualities of a good leader is the ability and desire to develop their employees. Taking an active role in the development of your team demonstrates confidence and concern for the future of the organization.

Unfortunately, many organizations do not plan properly for the development of their people and teams. People development without proper planning in place normally results in internal and external conflict, which leads to confusion, low productivity, less motivation, and therefore loss in various ways. When the right plan for development is designed based on the employees’ needs, desires, and potential the expected positive outcome will be achieved.

You can’t move forward if you don’t grow and you can’t grow if you never leave your comfort zone. When possible, give your employees challenging assignments. Help them prepare by providing them a safe environment to learn from the mistakes that they are bound to make.

Most people want to learn and grow their skills at work. Encourage experimentation and taking reasonable risk to develop employee skills. Get to know them personally. Ask what motivates them. Ask what career objectives they have and are aiming to achieve. You can make their career.

In order to get the most from your employees, you need to invest time and resources in their development. Annual performance reviews simply aren’t enough. Make a point to sit down with each employee on a monthly basis (or more frequently, if possible) and provide them with specific feedback and areas of improvement.

Creating a positive learning environment will encourage development and help your employees gain confidence in their position. Learning should be relaxed and clearly explain the reasoning behind every new exercise and lesson. Negativity will only inhibit the learning process, so it's important to be patient, allow for mistakes, and always reward new achievements. This positive feedback will reinforce and affirm the efforts of your employees, and encourage them to continue learning.

Remember, as a manager, one of your primary duties is to develop your people. Your employees are your most important resource.


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Wednesday, October 7, 2015

A Better Way: Leadership, Development, and Engagement - Northeast Lean Conference Recap Day 2


Yesterday I shared a couple highlights from Day 1 of the 11th Annual Northeast Lean Conference. Today we’ll continue with a recap of learnings from day 2. The morning kicked off with a presentation from Norman Bodek who discovered and published many of the original Toyota works and an initiator of the Shingo Prize in 1988. His presentation was about how to be a great leader/coach and how to have a wonderful life.

It is amazing what people are capable of doing if they can just believe in themselves and have a strong coach to support and guide them. The Harada Method teaches self-reliance, how to “stand on your own two feet." People pick a success goal, develop a time frame and plan out how to go about achieving the goal. This in itself is not easy, for most people are reluctant to pick a goal. They do not want to fail. But, using the Harada Method, people see the advantage of having a personal success goal that is linked to the corporation's vision. They then can see the purpose and value of their new goal and, with your help as coach/mentor, they work on a process to achieve it. Much like athletes striving to win a championship, employees write down their goals, write out a step-by-step plan to attain their goals, measure themselves against their goals and receive guidance and feedback. If people follow this plan, they will be absolutely successful.

The Harada Method is now recognized as one of the most systematic ways to enhance human resource development. With the Harada Method, you think of the purpose whenever you set a goal and you align these by setting target dates, measuring progress, sustaining efforts through written purpose and value statements, analyzing past successes and failures, establishing new routines to break past habits, preparing a daily journal to schedule your work life and keep you focused on your growth goals. You grow enormously and you learn how to be a great leader to coach others to improve both their lives and to their work performance.

The presentation was by Mike Martyn, a Shingo Award-Winning Author of “Own the Gap.”  At the heart of a leader's role in creating a CI culture is their ability to coach and develop their people. But the role management systems play in creating opportunities for leaders to connect with their people on a daily basis is frequently overlooked. He introduced principle-based management systems that create an environment of team-based problem solving and daily kaizen. He shared examples of how successful implementation of the “4-Key Systems" by leaders can bring about ideal behaviors, increased buy in and heightened engagement by their people in the change process to take their culture of daily kaizen to the next level.  

The four key systems of management that engage people to improve:
·        Strategy (Hoshin Kanri) – alignment is key
o   What does it mean to win?
·        Gaps – visual gaps, coaching for improvement
o   Are we winning?
·        Problem solving – system to solve problems routinely, improvement teams
o   What are we doing about it?
·        Standard follow-up – management support teams, make sure first 3 are working well
o   How can I help you win?
o    
It boils down to creating actionable gaps and systemically closing the gaps. The “experience” you create matters so engage everyone in the transformation.

The last presentation was team effort by Jamie Bonini, VP of Toyota Production System Support Center, and Bruce Watkins, GM of Karl Storz. They shared the story of transforming a complex endoscope production line to true single piece flow. The process not only involved a great deal of analysis and process improvement, but also a sea change in leadership at every level and department. A key to creating a problem-solving culture of continuous improvement at KARL STORZ Endovision (KSE) was the intense engagement of senior leaders under the guidance of coaches to learn and practice a new way of managing. Leaders should adopt TPS as a way to strengthen the quality, safety and productivity of their production system.

Bruce Hamilton closed the conference as he usually does by inspiring all of us to action.  He said we need to share within our community.  I took that to heart sharing my learning at the conference last week over these past 2 days.  I hope you’ll find some gold (value) in these nuggets that will help you put the pieces together.


Next year’s conference will be in Worcester, MA so get ready for another wonderful event by GBMP!

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Tuesday, October 6, 2015

Skills, Habits, and Behaviors for Improvement - Northeast Lean Conference Day 1 Recap


Last week I spent a couple days at The 11th Annual Northeast Shingo Prize Conference in Springfield, MA.  The wonderful conference hosted by GBMP was an exhilarating learning experience for me so I thought I would share some of those nuggets with you.

The first presentation was from my friend Dan Markovitz about his new book Building a Fit Organization. Everyone knows that in order to reach optimum levels of health, you have to exercise―and that you have to keep at it, day after day after day. No big secret here.  It’s the same with process improvement, and, specifically, lean processes.

Key principles include of improving your organization along the fitness analogy:
1)              Committing to Fitness/ Improvement
a.     The coach/leader needs to how to drive out fear
b.     Spirit – i.e. Paul Akers 2 second lean, Improve yourself every day
2)              Don’t focus on weight loss (waste) focus on strength/power/ fitness (value creation).
a.     Don’t focus on cost cutting
3)              Think Horizontal not vertical (training for a specific event) (focus on end goal)
a.     Think of the end result, what does your customer need
b.     The value stream map is the tool that gets you there
4)              The Right way to do things (Standard work)
a.     There is a right way to train for the event, don’t get caught up in the chaos.
b.     Focus on what is important and not in adminastrivity of business.
5)              Real Time feedback (Visual Management)
a.     Fitness facilities have mirrors everywhere
b.     How can you see ahead or behind and when do you react
6)              Coaching
a.     The coach/trainer is always there.
b.     Coach must be involved, know what the team is doing
c.     It is vitally important for management to be present.
d.      
Another presentation on developing cultural habits for success by Tim Crocker was particularly interesting. Frequently well-executed process improvement rollouts are unsuccessful. Often this result is due to required skills and habits missing from the culture – not faults in the methodology of the implementation. The specific cultural habits are coaching, communication, service orientation, personal accountability, results orientation, and simplification.

·       Communication
o   Core competency, meeting structures, relationships & emotional intelligence
o   Determine cultural norms for communication – face to face, phones before email, meetings with agendas, silence cell phone, never reply all
o   Use a Tier meeting system – daily to monthly at specific levels of business – map out your structure
·       Coaching
o   Routine (1on1), mentoring, focus on habits and behaviors not results, foster a mindset that craves feedback, use worksheet
o   Understand the change denial curve,
·       Service Orientation
o   Servant leadership, doing more than required, a belief that you can make a difference, do better for the team.
o   Share power and empower your team, be goals focused, people development, not results focused
·       Personal Accountability
o   Defined responsibilities, clear expectations, and clear ownership
·       Results Orientated
o   Practice and recognize habits, develop shared mental models, reward the right habits
·       Simplification
o   Habit or practice to use, visualize information

Changing your organizations culture and implementing a major project concurrently makes the difficult nearly impossible. Developing these habits in advance of the roll out, or any major effort, increases the chance of success. The habits can be developed and codified through drafting community of practice guide that sets methods and expectations. There are specific techniques, training, and workshops to improve and align each of these foundational cultural habits. These are all skills that can be learned and developed at all levels of the organization.

The last presentation of the first day was from Ariens President and CEO Dan Ariens. Dan shared his experience and lean journey over the last 15 years leading the company’s Lean transformation. He believes Lean initiatives are the heart of American business and the core of its future. The Ariens Company opened it’s doors to Thedacare to start the Lean Healthcare revolution.

A Lean journey at its best represents disciplined chaos and those who work at implementing long-term change understand this contradiction well. But Dan Ariens credits this chaos for providing an opportunity for everyone in an organization to become a Lean leader.

The 7 behaviors of a Lean Leader from Ariens perspective:
1)     Servant Leaders – are you masters of people or a person of masters
a.     Be honest
b.     Be fair
c.     Keep our commitments
d.     Respect the individual
e.     Encourage intellectual curiosity
2)     Relentless Change
a.     Leaders must be comfortable in environment of relentless change
3)     Disciplined Chaos – You must be disciplined in the chaos
4)     Benevolent Dictator
a.     Be very disciplined about how things are dealt with in company, rules
5)     Fearless Anxiety
a.     Lots of pressure on a leader – you have to face the anxiety, be fearless
6)     Cultural Revolution
a.     Leadership commitment – need to have great leadership to transform
7)     Confident Humility
a.     When you start to feel good about yourself you lose passion – you lose steam
b.     Continuous drive for improvement, it’s a journey, that’s what is important
c.     “Constant pursuit for perfection but along the way knowing you never reach it but finding success along the way” – Vince Lombardi.


Stay tuned tomorrow I’ll share some highlights from the second day of the conference.

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Monday, October 5, 2015

Happiness Formula In Three Simple Steps

Most people believe that happiness arises from suitable conditions, and that to be happy requires one to find, for example: a good job, a nice house, a new car, etc. However, it is actually more effective to rely on intrinsic ways of finding happiness, rather than through these extrinsic, object-oriented ones. Being happy is actually achieved mostly through one’s behavior and outlook rather than material, situational means. This is why it’s important to start cultivating healthy habits.



Google engineer Chade-Meng Tan is on a mission to make the world more peaceful and people happier. The secret to happiness, he says, is in doing three things every day.

Step one is to “calm your mind” by pausing during the day and paying attention to your breath. Meditation and mindfulness have been shown to offer numerous benefits.

Step two is to “log moments of joy.” All too often we focus on the negative and ignore or overlook the positive moments. Acknowledge more of the good things to counterbalance the negatives.

Step three is to “wish other people to be happy.” Being altruistic can turn around a bad mood and empathy is a very valuable skill. Remind yourself to wish for others’ happiness could, in turn, boost yours.


The video above is Meng talking about some of these concepts at Google’s “Search Inside Yourself” course. Although these three simple steps might not work for everyone, it’s worth a try if it means experiencing more joy.

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Friday, October 2, 2015

Lean Quote: Creating A No Blame Environment

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.

"Don’t find fault, find a remedy.— Henry Ford

Our greatest fear is the fear of being humiliated. So it’s not surprising that folks hide their mistakes and avoid saying and doing unusual things so they won’t be ridiculed. And yet, these unusual things – and what we can learn from our mistakes – may be just what’s needed to solve a problem.

Everyone’s contribution is needed. We can’t tolerate the old thinking of looking for someone to blame. No-blame environments produce decreased problems, fewer defects, increased productivity, higher profits – and – more genuine employee involvement and ownership. In short, work becomes a more fun place as the focus switches to satisfying the customer by achieving results. A no-blame environment does not mean people aren’t accountable – far from it . . . they are more so. And proud of it!

Follow these key points to build and grow a no-blame environment:

  • You build a “no-blame” environment every day – one conversation at a time. Use every conversation as an opportunity to build another’s self-esteem.
  • Managers and workers are partners in the improvement process. They share facts daily through straight talk and generous listening.
  • Mistakes are part of the “facts” in everyone’s work life. Use mistakes as opportunities for improvement – not vehicles for discipline.
  • Emphasize fact finding, not fault finding. Fact-finders observe, listen, ask questions, reserve judgement, analyze and conclude the facts. They replace the words “I think …” with, “Here is what the data tells us …”
  • Point fingers only at processes – not people.
  • Managers are responsible for creating a safe-from-ridicule, no-blame environment of trust & integrity. Their role is to coach & lead by example.
  • Workers are responsible for supporting & reinforcing the positive behaviors of fellow workers & management.

You start the process by beginning to live it. Remember, real change takes place through the conversations we have every day with each other. It is in your own best interest to make every conversation an opportunity to build another person’s self-esteem. This approach can work wonders in your company.


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