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Friday, July 15, 2016

Lean Quote: Lead by Example

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.

"You don’t lead by pointing and telling people some place to go. You lead by going to that place and making a case.— Ken Kesey

Whether you realize it or not, if you're a leader, your employees are watching every move you make. Good leaders must lead by example. By walking your talk, you become a person others want to follow. When leaders say one thing, but do another, they erode trust--a critical element of productive leadership.

Leading by example sounds easy, but few leaders are consistent with this one. Successful leaders practice what they preach and are mindful of their actions. They know everyone is watching them and therefore are incredibly intuitive about detecting those who are observing their every move, waiting to detect a performance shortfall.

Leaders must lead with their actions as well as their words. Leaders can effectively translate intention into reality by acting on the concepts and messages they teach and the things they say to those around them. Leadership is the act of setting the right example for those who follow. Leadership is about actively demonstrating your belief, not just talking about it. People who say one thing but do another eventually lose credibility.

Leaders are not afraid to jump into the ‘trenches’ and do some of the work themselves. They 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.


When you “walk the talk,” your behavior becomes a catalyst for people’s trust and faith in you. And it also emphasizes what you stand for. Leading by example shows people exactly what you expect and gives them living proof that it can be done. On a deeper level, leading by example and being as good as your words builds trust. It’s a sign that you take what you say seriously so they can, too.


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Wednesday, July 13, 2016

Lean PD App


Paul Akers has developed a new app that is a simple and elegant way to develop powerful daily habits. The Lean PD app (available in the App Store and Google Play) is the most effective way to develop yourself! Lean=efficient or elimination of waste. PD=personal development. So, Lean PD is the efficient way to personally develop yourself to reach your maximum potential. The whole concept is based on the idea of developing daily habits that support your BHAG (Big Hairy Audacious Goal). You will enjoy how simple and easy it is to transform your life by performing daily habits that support your goals.

Lean PD asks you to create a list of tasks you want to perform every day within a group of categories such as health, spirituality, exercise and leadership, among others. The App automatically logs tasks as incomplete, all you need to do is check the ones you completed and every night at midnight, the whole thing resets, so you start fresh every day. It is very elegant and simple, with very little management required. The Lean PD App allows you to view your daily, weekly, monthly and yearly progress so you get the big 40,000-foot-view. It graphically shows you how you’re performing in every category, so you know exactly where you need to improve.




The Lean PD App helps you be very deliberate about the things you eat and about the habits you’re developing on a daily basis.  If you’re pre-disposed to wanting to check things off and develop some healthy habits, the Lean PD App might be a great tool for you. It is simple, elegant and effective...everything we strive for when implementing Lean.
 
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Monday, July 11, 2016

Reprise: The Seven Basic Quality Tools

Pascal Dennis recently said that the so-called ‘Seven QC Tools’ aren't second nature to everybody. I couldn't agree more with Pascal. In that spirit, I'll describe these core tools & how they can help.

The Seven Basic Tools of Quality is a designation given to a fixed set of graphical techniques identified as being most helpful in troubleshooting issues related to quality. They are called basic because they are suitable for people with little formal training in statistics and because they can be used to solve the vast majority of quality-related issues.

The tools are:
  1. Check Sheets – A generic Tool which can be used for collection and analysis of data. A structured and prepared form that can be adapted for wide variety of issues
  2. Control Charts – This is a graphical technique,which can be used to study the changes to a process over time
  3. Pareto Chart – This is another graphical technique, which can be used to identify the significance of individual factors
  4. Scatter Chart – This is used to identify the relation between variables, by plotting pairs of numerical data, with one variable on each axis. The points will be falling on a line or a curve, if the variables are related.
  5. Cause and Effect Diagram (Also called as Ishikawa Diagram or Fishbone Diagram) – This can be used to structure the brain Storming Sessions. It is used to sort ideas into useful categories. Many Possible Causes are identified for a stated problem and the effect on the problem are identified
  6. Flow Chart (Stratification Charts) - This tool is used to identify the patterns within the data collected from multiple sources and clubbed together. It is used to identify the meaning of the vast data by identifying patterns.
  7. Histogram – It looks very much like a bar chart. it is used to identify the frequency of occurrence of a variable in a set of data.

The following presentation introduces the 7 basic quality tools:



Most organizations use quality tools for various purposes related to controlling and assuring quality. Although there are a good number of quality tools specific to certain domains, fields, and practices, some of the quality tools can be used across such domains. These quality tools are quite generic and can be applied to any condition.

The seven basic tools of quality can be used singularly or in tandem to investigate a process and identify areas for improvement, although they do not all necessarily need to be used. If a process is simple enough – or the solution obvious enough – any one may be all that is needed for improvement. They provide a means for doing so based on facts, not just personal knowledge, which of course can be tainted or inaccurate. Ishikawa advocated teaching these seven basic tools to every member of a company as a means to making quality endemic throughout the organization.


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Friday, July 8, 2016

Lean Quote: We Cannot Have Thinking Without Facts

On Fridays I will post a Lean related Quote. Throughout our lifetimes many people touch our lives and leave us with words of wisdom. These can both be a source of new learning and also a point to pause and reflect upon lessons we have learned. Within Lean active learning is an important aspect on this journey because without learning we can not improve.

"We can have facts without thinking but we cannot have thinking without facts.— John Dewey

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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Wednesday, July 6, 2016

Lean Tips Edition #97 (Tip # 1456 - 1470)

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 #1456 - Choose Courage Over Fear.
To be successful, you have to have courage. And to become courageous, do courageous things. Much of being successful is about going beyond what you think you're capable of -- venturing into the unknown. Whether you fail or succeed, you will learn and grow. Growth, in and of itself, means attaining a level of success whether it came from success or failure.

Lean Tip #1457 - Be Willing to Take Risks.
There are no guarantees on any path to success in life or business. The unknown is always looming. Therefore, risk and education are often the mechanisms necessary for knowing more clearly if you're on the right path.

If you're afraid to risk, you will put limits on your success and stay where you're comfortable. You cannot get what you want if you don't risk rejection and go for what you desire.

Lean Tip #1458 - Show Appreciation for Your Employees.
Workers who feel appreciated will be more motivated and productive. Praise employees publicly during meetings. Give spot awards. Profile employees and their work in company publications. If an employee puts in extra work on a project, recognize this. If you fail to reward hard work, your employees will not work as hard.

Lean Tip #1459 - Create a Culture of Accountability.
If workers are given ownership of their work and know they will receive feedback, they will work more meticulously. Accountability also means giving workers a clear sense of the direction of the company and how their work contributes to driving the company in that direction. If they feel like their work matters, rather than just being cogs in a huge machine, they will work harder.

Lean Tip #1460 - Invest in Training Your Employees.
All your employees will benefit from training, as it both makes them more valuable employees and creates a sense of indebtedness to the business, which leads to harder work. Pay particular attention to supervisors and middle managers who are just stepping into leadership roles. They are the key to transmitting upper management's vision and organizing work in an efficient manner, so extra management training for these positions will go a long way towards improving company productivity.

Lean Tip #1461 - Empower Your People
As you develop strong relationships you’ll see frontline employees wanting to step up. This is your opportunity to empower them. Encouraging authority, accountability, and responsibility at all levels creates a high performance team. Your role as leader is not to micromanage every detail of your organization but to rely on hundreds or thousands of people, each working toward a common purpose to be willing to make important decisions, exercise discretion, and answer for those choices. Let your employees know you trust them implicitly. They’ll earn it.

Lean Tip #1462 – Be Authentic, Share Yourself
One of the places most leaders fall down on the job is being inauthentic. They’re afraid to be vulnerable and known to others. Leadership has created a mental barrier that separates them from other people. Be honest about who you are, where you come from, and what you value. If you manage to practice all the previous strategies but don’t share your authentic self, you can’t build lasting relationships. Frontline leadership is about creating, reinforcing, and nurturing strong relationships.

Lean Tip #1463 – Expect Resistance to Change
Do not be surprised by resistance! Even if the solution a project presents is a wonderful improvement to a problem that has been plaguing employees, there will still be resistance to change. Comfort with the status quo is extraordinarily powerful. Fear of moving into an unknown future state creates anxiety and stress, even if the current state is painful. Project teams and change management teams should work to address resistance and mitigate it, but they should never be surprised by it.

Lean Tip #1464 – Seek Mentors.
Mentoring should be a necessity when it comes to planning out the improvement and development of future leaders. Mentoring is a popular idea for growth when it comes to leadership training. Make sure that your employees' mentor-mentee relationships don't just happen in a vacuum, however. One of the best benefits of mentoring is knowledge transfer, so give mentees and mentors structured ways to share what they've learned from these relationships. Successful employees have multiple mentors, so by building on that network effect, you allow leaders to branch and ultimately thrive.

Lean Tip #1465 - Lead With Passion, Not With Fear
Whether it be a good environment or a tumultuous one, leaders should never turn to invoking fear. In fact, in times of intense tension I believe that patience is even more important. Communication, clear objectives and performance feedback are critical in turbulent business environments but a fear-invoking boss can work to make bad situations worse. Lead your staff in an inspiring and passionate way – don't let their work be motivated by fear of your wrath. Remember intensity is different than fear. You can show passion but don't let it turn into intimidation.

Lean Tip #1466 - Have a Strong Lean Improvement Strategy
You'll need a solid plan and some attainable targets before implementing Lean. Utilize checklists and to-do lists, and you’ll always be working towards a goal. Look at every step in your process from the customer’s perspective: Is all that you’re doing something that he or she would be willing to pay for? If not, it is time to get back to the drawing board.

Lean Tip #1467 - Get the Whole Team on Board
To get the greatest advantages out of Lean, the entire organization should adopt and promote its practices, and extend its influence to suppliers as well. You must involve the people who are the closest to the work and you must get support from senior management as well.

In order to get people motivated, they must value the goals set for Lean manufacturing. These goals must be challenging, yet obtainable for your employees. Further, always ask for feedback on these goals, as well as progress toward target attainment. Feedback should always contain measureable facts and figures.

Lean Tip #1468 - Discard Conventional Fixed Ideas
Part of problem solving is thinking “outside of the box.” Encourage fresh perspectives and ingenuity in your team in order to develop innovative ways to forward Lean manufacturing without changing what is already efficient and successful. With such a rapidly evolving climate in manufacturing, sometimes conventional thought is what leads to the problem in the first place!

Lean Tip #1469 – Don’t Just Talk About it, Do it!
Once you have a Lean strategy in place, put it into fast and thorough action. Naturally, implementation is what ultimately yields results and improvement. The last think you want is to devise and formulate a Lean campaign that then sits on the shelf and collects dust. Run with your Lean plans as soon as you have everything nailed down.

Lean Tip #1470 - Concentrate on Bad Processes, Not People

By concentrating on the processes and building continuous improvement, you will have the culture change that you are looking for. Also, correct mistakes immediately. Don’t wait for the next shift, the weekend or maintenance to do it.

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Monday, July 4, 2016

Celebrating Independence and Lean Thinking


Independence Day, commonly known as the Fourth of July, is a federal holiday in the United States commemorating the adoption of the Declaration of Independence on July 4, 1776, declaring independence from the Kingdom of Great Britain. Independence Day is commonly associated with fireworks, parades, barbecues, carnivals, fairs, picnics, concerts, baseball games, family reunions, and political speeches and ceremonies, in addition to various other public and private events celebrating the history, government, and traditions of the United States.

Today, we celebrate and enjoy the freedom that comes with the event that made this day so special. Independence Day is a patriotic holiday for celebrating the positive aspects of the United States. Above all, people in the United States express and give thanks for the freedom and liberties fought by the first generation of many of today's Americans.

Freedom is not just the natural right of every human. It is the state of mind that enables people to create the greatest and the most inspiring things. The spirit of freedom gives us the power to conquer new heights, whether it is a real mountain peak or a bold business challenge.

Lean manufacturing provides your workforce the freedom that they need to own and maximize their productivity. In a Lean production plant, the "freedom to control one's work" replaces the "mind numbing stress" of mass production. Armed with the skills they need to control their environment workers have the opportunity to think actively even proactively to solve workplace problems.

Lean is all about finding better ways to do things, so that they require less effort, less time and fewer resources. It is not about cost reduction – penny-pinching, cutting investment, taking out people – it is about finding better ways to get work done. It is about developing a mindset, methods and tools to identify and eliminate waste in all its forms at every opportunity. It is about freeing-up resources because you no longer need to use them.

Lean Manufacturing is a business method that extends employees independence.  It provides more employees with the tools, methods and authority to make decisions. It creates teams to measure progress and devise new techniques. This leads to higher employee motivation and productivity

as workers are asked to come up with solutions to problems as opposed to having to work with flawed procedures. There is much to be said for greater worker independence in the execution of a lean philosophy. We may not have a day to celebrate like the US but the message is no less important.


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Friday, July 1, 2016

Lean Quote:Growth and Development of People is the Highest Calling of Leadership

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 growth and development of people is the highest calling of leadership.— Harvey S. Firestone

Your role as a leader is to develop talent to the highest levels of independent and autonomous thinking and execution. Great leaders don’t subscribe to a “Do-It-For-You” methodology of talent management, rather they lead, mentor, coach and develop team members by getting them to buy-into a “Do-It-Yourself” work ethic. Great leaders view each interaction, question or even conflict as a coaching opportunity. Don’t answer questions or solve problems just because you can, rather teach your employees how to do it for themselves. If you make it a habit of solving problems for people, you simply teach them to come to you for solutions at the first sign of a challenge.

Leaders facilitate the solution of problems by pinpointing responsibility and developing employees. Leaders do not solve other people’s problems. Similar to the fishing adage, which says don’t feed a person a fish; teach them how to fish, don’t solve the problem, teach them how to solve their own problems.

Lean thinkers at Toyota believe that showing respect for people means you allow them to think for themselves and solve their own problem. It is often said that the mission of Toyota is about developing exceptional people who happen to make great cars. The point is that it is more about people and less about the problem. The problem is another opportunity to teach them a skill for lifetime.


Develop exceptional people and teams who follow your company's philosophy. Empowerment happens when employees use the company tools to solve problems. Build cross functional teams to improve quality and productivity. Work hard to reinforce the company culture and assure it is followed over the course of years.



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