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Monday, December 20, 2021

Lean Tips Edition #181 (Tips #2926 - 2940)

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 #2926 – Celebrate Failures

A colleague of mine used to say, “problems are treasures.” That is the mentality you need to celebrate failures and red dots. They are treasures because they provide the opportunity to improve the standards and processes you have in place. When you seek perfection, no defect is acceptable.

When a problem occurs front line staff should not only be encouraged to bring it up, but they must be given an outlet to do so. Leaders must remember to not place blame but should foster a safe environment that encourages PDSA thinking.

Lean Tip #2927 - Share More, Not Less.

Even in a small company, silos emerge. A policy of more sharing will help everyone stay in touch with what others are doing, and create a collective expectation. Keeping everyone pointed in the same direction is hard; sharing more about what’s going on, how you’re doing things, reasoning behind decisions, etc. will help.

Lean Tip #2928 - Don’t Be Afraid to Ask “Why”

So many people are afraid of the question “why.” Does that sound like you? Stop being afraid, there is nothing wrong with asking why. By asking why you will be able to discover what the base of the task is that you want to accomplish will help you understand it better.

By understanding why something needs to be done, your chances of completing the task from start to finish will increase. Also, you should also consider the fact that by asking “why” and learning the reason behind it, you will be adding to your knowledge.

Lean Tip #2929 - Make Improvement Easy

If you want to build a strong continuous improvement culture, then it’s vital to make it easy for your employees. Turning actions into habits means they need to happen seamlessly and that requires the removal of any potential barriers. Lack of time and resources are two of the most frequent challenges so managers need to address them early on. Create a process that’s quick to follow by keeping it as simple as possible. Support employees with the tools they need to make suggestions, track the progress of ideas, and even execute improvement projects themselves. Using a software platform is an easy way to do this since it integrates the entire improvement process into one tool (along with management systems to track results). 

Lean Tip #2930 - Focus on Execution

Focusing on execution is one of the quickest ways to develop a culture of continuous improvement. Many companies get bogged down by processes and have long reviews which lead to bottlenecks and delays. This causes frustration for everyone involved and means that people lose faith in the concept. Organizations with a strong improvement culture do something different – they focus on execution. They take a lean management approach by simplifying processes and speeding up the workflow. Businesses like this are able to implement the vast majority of ideas which builds confidence in the philosophy until it eventually develops into a company-wide culture. Even bad ideas will usually highlight a good improvement opportunity so act on suggestions quickly to build momentum.

Lean Tip #2931 – Look Outward, Not Inward.

People are more likely to feel grateful when they put their focus on others, rather than getting caught up in their own inner narratives about how things should have gone. Empathy for others can trigger a sense of gratitude, and people who have an outward focus tend to experience stronger benefits.

Lean Tip #2932 – Savor The Good Moments.

If you notice you’re feeling happy, stop what you’re doing and pay attention for a few minutes. Notice exactly how you feel, including the sensations in your body and the thoughts you’re having. Later, when you’re trying to inspire gratitude, you can remember this moment and experience the benefits all over again. 

Lean Tip #2933 – Celebrate The Small Wins.

It sounds simple, but celebrating small wins at work is a great way to practice gratitude. Celebrating small wins increases productivity by activating the reward portion of the brain. This leads to feelings of pride, happiness and accomplishment. It also makes us want to press on and achieve our next goal.

Celebrating small wins and activating the reward portion of your brain can be as easy as crossing something off your to do list. If you have a big project or assignment to work on, try breaking it down into smaller portions. As you complete each portion, celebrate the small win of getting one step closer to completing the bigger project.

Lean Tip #2934 – Notice More.

Taking some time to reflect on how you see the world and your place in it will give you the opportunity to see what you may not have noticed before. Unfortunately, we often don’t appreciate our blessings or opportunities until we no longer have them. Just taking time to notice what you have should improve your gratitude in the moment.

Lean Tip #2935 – Make Gratitude A Choice, Not A Reaction

Try not to wait for good things to happen to demonstrate your gratitude. Think of gratitude as your underlying foundation; operate from a place of being thankful, even without an outside prompt or motive.

When life doesn’t go quite the way we envisioned it, we can fall into a pattern of self-pity and lament. We begin to view our circumstances as a curse or a trap, rather than remembering the many things around us that we can be grateful for. Shift your focus to the hidden opportunity in every situation you perceive to be negative.

Lean Tip #2936 – Encourage Creativity

Intellectual stimulation is one of the leadership qualities that define transformational leadership. Followers need to be encouraged to express their creativity. Effective leaders should offer new challenges with ample support to achieve these goals.

One way to foster creativity is to offer challenges to group members, making sure that the goals are within the grasp of their abilities. The purpose of this type of exercise is to get people to stretch their limits but not become discouraged by barriers to success.

Lean Tip #2937 – Encourage People to Make Contributions

Let the members of your team know that you welcome their ideas. Leaders who encourage involvement from group members are often referred to as democratic or participative leaders. While they retain the final say over all decisions, they encourage team members to take an active role in coming up with ideas and plans.

Lean Tip #2938 – Keep Trying New Things

Who says leadership is a one-way relationship? As you work toward developing some of these leadership qualities, don't forget to look to your followers for feedback and inspiration. Pay attention to the things that have been effective in the past and always be on the lookout for new ways to inspire, motivate, and reward group members.

Lean Tip #2939 – Have a Positive Attitude

Transformational leaders have an upbeat, optimistic attitude that serves as a source of inspiration for followers. If leaders seem discouraged or apathetic, members of the group are likely to also become uninspired.

Even when things look bleak and your followers start to feel disheartened, try to stay positive. This does not mean viewing things through rose-colored glasses. It simply means maintaining a sense of optimism and hope in the face of challenges.

Lean Tip #2940 – Serve as a Role Model

Transformational leaders exemplify the behaviors and characteristics that they encourage in their followers. They walk the walk and talk the talk. As a result, group members admire these leaders and work to emulate these behaviors.

Research suggests that leaders are able to foster a specific belief and then transmit that inspiration to their followers.

 As a result, followers are optimistic and have high standards for performance and achievement.

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Friday, December 17, 2021

Lean Quote: No Replacement For Family Time

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.


"No amount of money or success can take the place of time spent with your family.  —  Unknown

Modern life is more fast-paced than ever, and we’ve all got a lot of day to day demands on our time. From work stresses to parental responsibilities, finance worries and important calendar dates, we could all definitely use a break every once in a while!

The holidays are the perfect time to gather with loved ones-- sharing stories that ignite laughter and good cheer. Engaging in these precious moments with family and friends is not only enjoyable, it’s also beneficial to your health.

Family time offers many benefits, including building confidence, creating a stronger emotional bond between family members, improving communication skills, better performance in school and reduced behavioral issues, as well as providing an opportunity to make memories built on fun, laughter and togetherness.

No matter how you choose to unwind, it will be difficult to do if you are still thinking about work even when you’re out of the office. The first thing you should do as you step out of the office is to turn your work phone off. Avoid bringing work home with you. You deserve to save some time for yourself and your family after putting in most of your energy for the day into the office.

One of the most important benefits of spending time together is also one of the simplest: creating memories that will last a lifetime. Whether it's playing a game together, attending an event, going on vacation or just sitting in the living room or around the table talking and laughing, positive memories are beloved possessions that give family members a sense of belonging and can help reinforce the importance of family.

Prioritizing family over other obligations is an important element of finding quality time together as a family. This may mean establishing work boundaries and taking time away from technology. But, protecting your family time will help keep your priorities straight and will ensure a happier, better-adjusted family.

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Wednesday, December 15, 2021

Top 10 Posts from 2021

The end of the year is traditionally a time to look back and reflect. One way to reflect is to evaluate popular blog posts. I have been taking time to reflect on the year that was and as part of that reflection I have flipped back through the 150 blog posts I have written so far this year and compiled a list of my Top 10.

10. Obeya: The Lean War Room - Obeya rooms provide big gains in both collaboration and problem solving, two features that are essential in project management.

9. The Power of Reflection In The Workplace - Reflection is fundamental to our growth and development, especially in developing higher mental functions such as problem solving and decision-making skills

8. 10 Traits All Great Leaders Possess - Collection of characteristics from great leaders in business, sports, politics, and the military.

7. Five Ways You’re Stifling Employee Engagement - Top reasons why employees are not motivated to contribute their best efforts at work. 

6. The Benefits of Lean Visual Project Management - Why you need to be using visual project management techniques over traditional project management tools.

5. 7 Tell-Tale Signs of Leadership Mismanagement - Take notice of the signs of a bad company culture (mismanagement).

4. Using the Gemba Walk to Learn and Engage - The gemba walk is a management process to learn more about the actual condition and to engage with employees on continuous improvement.

3. What Makes A Great Team? - Build a great team that will work together and produce results with these 9 surefire characteristics and attributes.

2. Six Practical Tips for Developing an Engaged Workforce - Use these six tips to help you develop an engaged workforce in your company..

1. The Foundation and Principles of Lean Thinking - The principles, rules-in-use, and foundations of Lean establish a process for everyone to contribute at or near their full potential.

What were some of your favorite Lean posts from 2021? Any recommendations for next year?



Thanks for your continued readership in 2021. I hope you enjoy the holiday season and go on to achieve Lean success in 2022.

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Monday, December 13, 2021

10 Reasons for Unnecessary Costs that Lead to Poor Value

There is little doubt that engineers and designers are well aware of the need to minimize cost, and in most instances, they are anxious to receive and use better cost information. However, there are other reasons why unnecessary cost occurs in the products they are specifying.

The most frequent reasons unnecessary cost is found in a product or system will normally fall into one or more of the following categories:

Lack of an Idea: Unnecessary cost can be built into a product or service  simply because of our failure to utilize creative ability in developing alternative solutions. In many cases, we accept the first workable solution that comes to mind.

Lack of Time: Speed to market demands often produce short product development cycles. Aggressive deadlines can sometimes prevent the optimum design from emerging. Decisions we are forced to make, perhaps due to an urgent delivery, or tight design, or product schedule, can force us to initiate a temporary circumstance or satisfy a requirement without regard to cost. Many times, these temporary measures become a fixed part of our product or service, resulting in unnecessary costs year after year.

Lack of Information: Lack of information on exactly what function we are trying to perform. Lack of information regarding what the customer wants or needs. Lack of information on new materials, products, or processes. Lack of cost information or what is necessary cost that is needed to generate a profit.

Reluctance to Seek Advice: Some people are not willing or able to look beyond the current horizon and are reluctant to seek or ask questions, feeling embarrassed or inadequate if they admit they do not know something. This often drives the inability to utilize new technologies and materials. The “Not Invented Here” syndrome does not allow people to tap into ideas from other outside sources.

Temporary Circumstances  or Emergencies: Most companies are faced with emergency measures at some time when a material, machine or supplier readily available is accepted as a temporary solution regardless of cost and continues in use after the emergency has been overcome.

Honest Wrong Belief: Unnecessary costs are often caused by decisions made on what is believed to be true, and not on the facts. We let ourselves believe that there is a good reason why we should not do something: The tools are too expensive; a particular material is not good to work with; that plastic is brittle. “Honest Wrong Beliefs” can stop a good idea that may provide a more economical product or service.

Habits or Inertial Thinking: Doing things almost by rote, each time a similar problem occurs that has been addressed before. We must face the fact that some of our habits need review. We must recognize that old habits can be changed, that new habits can be developed, and more importantly, if we are to eliminate the unnecessary costs, we will have to base our business decisions on fact and not on our habits and attitudes.

Negative Attitudes: Failure to recognize creativity or innovation.

Obsolete Specifications: Some specifications used today are outdated. Testing specifications, codes, material specifications, and specification from previous projects are used unquestioningly.

Poor Human Relations: Lack of good communication, misunderstanding, interpersonal relations between people are a frequent source of unnecessary costs.

These reasons for unnecessary cost probably apply to most aspects of human activity. They will and do occur in well-organized companies having skilled management and technical staff, and do not necessarily reflect on any one individual or group of individuals.


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Friday, December 10, 2021

Lean Quote: Gratitude Always Leads to Generosity

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.


"Christmas is more than a time of festivities, family, and friends; it is a season of generosity, gladness, and gratitude.  —  William Arthur Ward

With the year coming to a close, I wanted to take some time to reflect on the relationship between gratitude and generosity, remembering why it’s so important to express one just as frequently as the other. 

Gratitude and generosity are interdependent attitudes of mindfulness that engender and strengthen one another. They are powerful forces that act in the opposite direction of destructive emotions such as hatred, jealousy, greed, resentment and ill-will. Just as with the other attitudes of mindfulness, they can be cultivated through practice. 

Gratitude is a feeling of thankfulness for what we have received – acknowledging the good, especially that which comes from or exists outside of us. If we consider closely, we begin to realize that nothing good we possess, tangible or intangible, has been generated by ourselves alone. Gratefulness involves accepting what is, being in the now, and getting unhooked from “I, me and mine”. 

Generosity has been described as the act of giving oneself over to life. We can be generous with ourselves and with others, but acting generously with regard to the welfare of another acknowledges our interconnection and brings a special kind of joy. Generosity doesn’t always have to involve material things. One of the greatest gifts we can give is our attention. Giving thanks and encouragement, easing human suffering, acting in a way that helps equalize inequities, and creating social justice are all forms of generosity. 

Practicing gratitude and generosity are important for all who seek true happiness. 

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Wednesday, December 8, 2021

The Ultimate Guide to Lean Manufacturing

Originating on the assembly lines of Henry Ford's factories, then later refined by those that built Toyota into a world leading car manufacturer, lean manufacturing is the method by which manufacturers aim to reduce waste yet maintain productivity in their factories. The goals of lean manufacturing are to reduce the time, effort, and costs of making a good without sacrificing quality.

In this article from Propel, you can take a deeper dive into what lean manufacturing is, what its main goals and core principles are, and what are the major pros and cons of it. In many ways, lean manufacturing is the way factories and plants will continue to strive to operate. Its focus on low waste makes it environmentally friendly and the lowered production time makes us consumers happier, but implementing a true lean manufacturing process can be challenging and can sometimes require a true overhaul on the entire company.


Author Bio:
David Sides is the Outreach Director at Propel. We at Propel have made a tool that allows manufacturing companies to track its product across its entire lifecycle. Our expertise here along with our relationships have allowed us to have great insight into lean manufacturing and how it can improve the process.

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Monday, December 6, 2021

5 Tips For Creating a Culture of Experimentation



"Experimentation" has become a buzzword for managers and business owners. Everyone wants their employees to think outside the box, develop creative ideas and be innovative. However, few organizations actually take the steps necessary to make that happen. 

Since the beginning of times, experimentation has served as a critical tool for challenging the status quo business models and driving radical changes. For organizations, it typically means the potential to take bold steps and decisions to improve the customer experience while minimizing business risks. It also provides an organization with endless opportunities to learn more about their customers by means of testing. 

1. Be Data Driven 

Don’t make the mistake of not measuring your data for better results. Data is what confirms results, validates change, and fuels growth. 

Don’t ignore even the seeming negative data, or opinions of users. Use these to fuel your next innovative move. Your consumers and users may have completely different ideas of what could work better. Listen to their feedback and study the data. Then, trust in that data enough to be driven by it. 

2. Be Open to Ideas and Creativity 

It is easy to get stuck in your ways. Instead, adopt a company approach whereby you are all open to ideas and creativity. 

Don’t be afraid to take a different path, to try different software, or just to do something completely different. Sometimes the biggest anomalies or most outlandish suggestions can produce the best results. After all, if you aren’t changing you aren’t growing. And if you aren’t growing, your business cannot progress. 

3. Break Down Silos 

For a company hoping to evolve, nothing will kill progress like silos. In a culture that values experimentation, collaboration and sharing is imperative. This is why it’s so important that all team members, regardless of position or department, are given the opportunity to present ideas and pursue new innovative opportunities. 

Oftentimes, the team members who are closest to the customer possess the greatest ideas for growth, yet they’re too afraid to come forward. By offering these individuals a platform to express their ideas, morale will be boosted and a sense of entrepreneurialism will be instilled across all levels. 

4. Integrate Experimentation Into Day-to-Day Life 

To make experimenting a habit in your business, it needs to be intertwined into your employees’ day-to-day life. Impending deadlines, on-going projects, endless meetings – it’s hard to find time to experiment. It’s the number one reason why employees feel held back from learning. If you’re part of an organization, developing a experimenting culture, you have to be an advocate for time. The concept of experimentation should be ingrained in your employees from the moment they join your organization. 

5. Learn from Failure 

My last tip: don’t be afraid of failure. Strive to grow from past mistakes, think outside the box, and embrace experimentation, even if it means you don’t get everything right from the beginning. Stagnation is one of the dangers of companies that start well but end up resisting growth. 

A culture of experimentation and risk taking is great for any organization. It keeps fresh ideas and opportunities flowing through the organization, helping the organization to optimize operations and maintain their competitive edge. 

With the tips shared above, you will be able to effectively push your team to take risks and create a culture where experimentation is the norm rather than the exception. 

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