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Friday, February 9, 2024

Lean Quote: Willingness to Constantly Accept Critical Feedback

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.


"There has to be a willingness to constantly accept critical feedback and rapidly iterate to make things better.  —  Sam Yagan

Praise and constructive criticism help to develop and improve employee performance. At work, managers use critical feedback to improve the standard of work by creating an atmosphere that nurtures growth and support. If you're a manager or employer, learning how to give critical feedback effectively can help improve employees' overall productivity.

Tips for giving feedback:

Make time

  • Regardless how busy you are, create a feedback calendar and take it seriously!
  • If you become aware of a “positive” or “negative” action, acknowledge it immediately


Make it honest and meaningful

  • Be prepared to provide specifics about both negative and positive feedback
  • Think in terms of praise and constructive criticism – both contribute to growth


Use goal tracking

  • If you don’t know how to get started, review how the individual has helped (or hindered) the achievement of organizational or team goals


Discuss and document the top 3 strengths and 3 growth opportunities

  • For the strengths, try to leverage them and keep them sharp
  • For the growth opportunities, determine what actions can be implemented immediately, which require assistance (ex. Training/mentoring), and have a plan for tracking progress


Commit to supporting continual learning

  • Review what in house programs are available
  • Ensure your budget adequately includes development opportunities
  • Investigate external training that can address your focus areas

 

Feedback is critical for individual growth and for organizational success but it’s not always easy to give or to receive.

Wednesday, February 7, 2024

Tips for Running Effective Daily Management Meeting


Lean organizations make use of Daily Management systems, a structured process to focus employee’s actions to continuously improve their day-to-day work. Daily Management empowers employees to identify potential process concerns, recommend potential solutions, and learn by implementing process changes. Daily Management, if done right, can be a critical tool in any organization’s toolbox to engage frontline staff in problem-solving and to deliver customer value.

Here are my tips for running an effective daily management meeting.

Segregate Meetings With Management Levels (Tier 1, Tier 2, Tier 3)

It is important to segregate meetings with management levels (tier 1, tier 2, tier 3) because it allows for more focused and efficient communication within each level. Each level of management has different responsibilities, expertise, and decision-making authority, and holding separate meetings allows each level to discuss issues and make decisions that are most relevant to their respective roles.

Tier 1 meetings typically involve front-line supervisors and focus on day-to-day operations and problem-solving. Tier 2 meetings involve middle managers and focus on longer-term planning and strategy. Tier 3 meetings involve senior executives and focus on high-level strategic planning and decision-making.

Meet In Person Near the Gemba

These meetings should be conducted on the shopfloor in a safe area where communication is easily heard. While there are many digital solutions these days I prefer the manual versions.

Set a Time Limit

Time is of the essence in a factory, and employees often have limited time to spend in meetings. Therefore, it’s essential to keep these meetings short and focused. Aim for a maximum of 15 to 30 minutes and prioritize the most critical issues that need to be discussed.

Start with Positive News

Starting the meeting on a positive note can set the tone for the rest of the meeting. Begin by sharing any good news, such as meeting production targets, or recognizing team members for their hard work.

Safety is Next Concern

Safety is a top priority in any factory, and daily huddles provide an opportunity to discuss any safety concerns or near-misses that have occurred. Discussing safety measures can help prevent future incidents and ensure the safety of all employees.

Don’t Solve Problems in Real Time

An effective daily huddle makes it so someone can acknowledge that they can help a fellow team member without turning it into a troubleshooting session.

Capture Action Items

When action items are assigned, they should be owned by the person responsible for them. This should include specific tasks that need to be completed before the next meeting or when it will be completed.


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Monday, February 5, 2024

5 Continuous Improvement Ideas to Try Out

Maybe you don’t have buy-in from Executive leadership for a Lean transformation or maybe you do. You know your organization can fall behind the competition if you aren’t actively looking for ways to streamline and improve processes. One way you can combat this is by implementing continuous improvement or Kaizen. If you’re looking for ways to create a better organization, I’ve listed some continuous improvement ideas to try out.

1. Training & Development

If there’s one thing you should have for continuous improvement, it’s training and development. Training programs are one of the improvement tools that can give your employees more opportunities for development, growth, and engagement. It also provides an avenue to train them with the skills and knowledge your organization needs its workforce to have. For example, you can train them about process improvement training or business approaches like the Six Sigma and Lean to secure customer satisfaction and cost reduction. You can also take advantage of this program to teach them the best business practices to better execute current strategies and find ways to improve on them.

2. Daily Huddles

Daily huddles take place at the value stream level and last for about 10 to 15 minutes. Huddles are led by the leader and are attended by all members of the value stream. Huddles take place directly in front of the visual board so that the metrics that are displayed on the board can be discussed and updated as needed.

The purpose of daily huddle is to make everyone collaborate at a common platform, take charge and ownership of each and every aspect, for example, improving production, productivity, material availability, etc., and most important is the increasing communication.

3. Standard Work

Standard work is a written description of how a process should be done. It guides consistent execution. At its best, it documents a current “best practice” and ensures that it is implemented throughout a company. At a minimum, it provides a baseline from which a better approach can be developed.

The definition of standard work is “the most effective combination of manpower, materials and machinery”. Standard work is the method, and thereby you have the four Ms of manufacturing (manpower, material, machinery, methods). Standard Work is only “the most effective” until the standard is improved.

4. Value Stream Mapping

Value stream mapping is a tremendously valuable tool for improving a process. Well suited for a broad range of industries and processes. A value stream map (VSM) illustrates the flow of materials and information as a product or service moves through a process.

Value-stream mapping is a useful tool for grasping the current situation and for planning improvements. A current state value-stream map depicts the current situation as is. A future state value-stream map depicts what the value stream should look like after planned improvements have been implemented.

Kaizen is a Lean manufacturing tool that improves quality, productivity, safety, and workplace culture. Kaizen focuses on applying small, daily changes that result in major improvements over time. Although improvements under Kaizen are small and incremental, the process brings about dramatic results over time.

5. Hold a Kaizen

Beyond the obvious benefit of improving processes, holding a Kaizen event can foster problem-solving, collaboration, and communication skills and allow employees to demonstrate leadership. Engaging team members to identify problems and suggest improvements in their work areas encourages a sense of ownership over their work, which can improve overall motivation, morale, and productivity. Finally, holding a Kaizen event is one way to reinforce a robust culture of continuous improvement within your organization, after all, the best way to sustain the principles that you want to guide your company is to put them into practice.

You can try one of these or all of these. You’ll see benefits from these continuous improvement ideas and perhaps even spark a Lean transformation with your success.


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Friday, February 2, 2024

Lean Quote: Adopt a Growth Mindset

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.


"I think it’s very important to have a feedback loop, where you’re constantly thinking about what you’ve done and how you could be doing it better.  —  Elon Musk 

This is what tech entrepreneur Elon Musk refers to as his single best piece of advice. We should always be thinking about how we can evolve and grow, and this is why a culture where people practice giving and receiving feedback every day can be so powerful. It’s about having a growth mindset, where we see our skills as adaptable and believe they can be developed upon. And the good news is, we can all learn to adopt a growth mindset.

Building a new solutions and products is a highly innovative and creative process. Things simply don't go to plan all the time, setbacks and failures are inevitable along the way. What makes a difference is how a team deals with them. Each failure is an opportunity to reassess, make a change and try a different approach. In order to succeed, teams must become resilient to failure and focus on the learning outcomes that they present. When we feel that it is safe to fail we are more likely to try risker experiments, and sometimes these riskier experiments have huge payoffs.

The concept of the growth mindset was developed by the psychologist Carol Dweck and popularized in her book, Mindset: The New Psychology of Success. Dweck proposes that people deal with failure in two very different ways depending on their mindset. Some people have a fixed mindset and others with a growth mindset.

People with a fixed mindset believe their intelligence and talent are fixed traits. They believe that talent alone creates success without effort. They don't deal well with setbacks and they try to hide their mistakes.

In contrast people a growth mindset believe that their abilities and talents are just a starting point and that they can be developed through dedication, hard work and learning. They are keen to learn from the people around them. They respond positively to failure and are best described in one sentence: "I can't do that...yet".

Growth Mindset

Fixed Mindset

Failure is an opportunity to grow

I can learn to do new things

I like to try new things

Inspired by the success of others

Embraces challenges

Failure is the limit of my abilities

I'm either good or bad at something

I stick to what I know

Threatened by the success of others

Gives up easily

Teams that operate with a growth mindset have a much more malleable view of success. They do not view failure as a reflection of their ability but rather as a starting point for experimentation and testing of new ideas. They have a passion for learning and improving themselves and their team. They strive for continuous improvement and never give up.

Wednesday, January 31, 2024

Lean Roundup #176 – January, 2024



A selection of highlighted blog posts from Lean bloggers from the month of January 2024.  You can also view the previous monthly Lean Roundups here.  

 

The Pearls and Turds of Continuous Improvement – Kevin Meyer illustrates keys points of continuous improvement in small sequential steps and learning from failure from the documentary Stutz he recently watched.

 

What Conversations Does Your VSM Drive? – Mark Rosenthal discusses how the values stream map can change the conversation in your organization and drive continuous improvement.

 

Mastering Mistake-Proofing: Insights from Toyota’s Poka Yoke Approach – Mark Graban discusses Toyota's revolutionary approach to mistake-proofing, a concept that has redefined workplace efficiency and quality.

 

Many Ways to Win – Bob Emiliani says the passing of time, experience, and facts prove that we, collectively, were wrong to think of Lean management as a replacement for classical management on a widespread basis, given that there are many ways to win in business.

 

Embracing System-Level Problem Solving over Firefighting – John Knotts explores the paradigm shift from individual, ad hoc problem-solving to systemic approaches that empowers every employee to be a hero in their domain.

 

Complexity is a Crude State, Simplicity Marks the End of a Process of Refinement – Pascal Dennis explains the issues of complexity within strategy and advocates for simplicity.

 

Keep Calm and Stop the Line—Part 1 & Keep Calm and Stop the Line—Part 2 - Christoph Roser explains the reasons why you would want to stop the production line.

 

New Competency #3: How We Learn, Develop, and Improve - Christopher R Chapman reviews Peter Scholtes’ six new leadership competencies by taking a look at the third entry, Understanding How We Learn, Develop, and Improve; Leading True Learning and Improvement.

 

Why We Care So Much About Continuous Process Improvement - Maggie Millard shares 12 reasons why process improvement is so important and it’s role in different industries.

 

Are You Organized for Leadership? - Josh Howell reflects on a recent learning tour to Toyota and GE Appliances, sharing insights the group gathered about lean transformation.

 

Things I Have Learned – Bob Emiliani shares his learning about people and systems over the last 15 years in the Lean community.

 

Mastering Mistake-Proofing: Insights from Toyota’s Poka Yoke Approach – Mark Graban discusses Toyota's revolutionary approach to mistake-proofing, a concept that has redefined workplace efficiency and quality.

 

Cultivating a Culture of Learning: Overcoming Fear and Futility in Problem-Solving – Mark Graban shares a recent mistake he made that illustrates the two elements necessary to overcome these mistakes.

 

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Monday, January 29, 2024

Lean Tips Edition #294 (#3436 - #3450)

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 #3436 – Articulate and Communicate Goals Clearly

A great example of setting work goals is being able to communicate them to the team in an effective way. Often, ideas and professional goals may make perfect sense in the mind but when it’s time to share them with the team, it could be incoherent and incomplete.

The professional skills to articulate goals clearly requires leaders to have exceptional communication skills. Before sharing professional goals with the team, make sure it answers the following questions:

  • What? (The actual goal)
  • Why? (You want to achieve this professional goal because …)
  • Which? (Resources and skills that I need …)
  • Who? (Who will do the work? The team)
  • When? (Timeline/deadline for the goal)
  • How? (Steps/plan to achieve it) 

Answering these questions is a great way to ensure that the goals you have in mind are as ready as they can be in their draft version, before sharing them and improving them with your team.

Lean Tip #3437 – Make Goal-Setting a Team Exercise

The difference between a good leader and a great leader is that the former sets work goals for their team whereas the latter sets goals with their team. 

Team leaders that include team members in the process have a lot more to learn and a higher probability of succeeding. 

The reasoning is simple. Open conversations with your team create a constant feedback loop, refining the outcome every time. This can strengthen the communication channel between you and your team and make them feel included and understand how their work contributes towards the overarching goals. 

Lean Tip #3438 – Clearly Define Success.

Determine clear success criteria for your priority so you know what it looks like to achieve the goal. If your goal is a business one, ensure your expectations of success are aligned with everyone on the team. Everyone needs to agree on when we reach the goal to ensure that we are achieving success. We use a simple Red-Yellow-Green method to set clear success criteria:

  1. Red = Failure or unacceptable performance on the priority
  2. Yellow = Between Red and Green
  3. Green = Successful completion of the goal
  4. Super Green = Stretch goal

Lean Tip #3439 – Change Your environment to Meet Your Goals

In order to reach some goals that you have, change your habits. If you have organizational goals, then one of the first places you can start is by organizing your office and making sure that everything is ready to use.

Even some of your professional development goals can be tied to regular daily habits. For example, if you would like to increase employee engagement and team collaboration within your organization, you might have to start by simply thanking people for the work that they do.

Lean Tip #3440 – Redefine Your Goals When You Fall Short

Every single person on this earth has failed at some point in their life. What really matters is not when you fail, but what you do to affect change in your life. Ultimately, you have two choices: 1. You sulk when you don’t reach her goal, or 2. You pick yourself up and try again.

Lean Tip #3441 – Educate & Emphasize the Importance of Kaizen

Educate on the meaning of kaizen and emphasize a personal understanding of the philosophy of kaizen across all levels of the company. Building a company culture with a steady focus on improvement is critical to maintaining momentum in your kaizen efforts.

Lean Tip #3442 – Empower Your Employees in the Gemba

Employees who are closest to the problems in your operations are the best-equipped to solve them. They are your greatest assets in your kaizen efforts, so give them the support they need to implement improvements. Developing your team’s abilities through training and support should be as much a part of your continuous improvement program as making improvements to manufacturing processes.

Lean Tip #3443 – Document Your Process and Performance Before and After Improvements Have Been Implemented

In order to evaluate improvements objectively, existing procedures must be standardized and documented. Mapping the process’s initial state can help you identify wastes and areas for improvement and provide a benchmark for improvement.

Lean Tip #3444 – Standardize Work for Improvement to Last

In order for improvements to last, they must be standardized and repeatable. Standardizing work is crucial to kaizen because it creates a baseline for improvement. When you make improvements to a process, it’s essential to document the new standard work in order to sustain the improvements and create a new baseline. Standard work also reduces variability in processes and promotes discipline, which is essential for continuous improvement efforts to take root.

Lean Tip #3445 – Create Your Own Kaizen Guidelines

Reflecting on your kaizen efforts after improvements have been implemented is an important part of the continuous improvement cycle. As you reflect on your efforts, develop your own kaizen guidelines. Start by creating guidelines based on your own experiences improving the workplace. Keep in mind that these guidelines should be for your colleagues, your successors, and yourself to understand the problems you have overcome. These guidelines will ultimately help you as you approach your next challenge.

Lean Tip #3446 – Encourage Leadership to be Open-Minded

Continuous improvement works especially well when individuals are encouraged by senior leaders. Prepare your leadership team by offering special training to encourage new ideas and removing any blockers that may be in a team member's path as they are trying to improve a workflow.

Lean Tip #3447 – Don’t Make Perfection the Goal

One of the hardest parts of using the continuous improvement model is the desire to strive toward perfection. This is an impossible feat, and the philosophy behind kaizen is to make small changes to be better than you were the day before. Focusing on perfection can lead your team to make changes that aren’t actually necessary.

Lean Tip #3448 – Troubleshoot in Real Time

One of the most useful concepts in continuous improvement is the encouragement to confront problems head-on in an effort to solve it faster. If an issue becomes apparent fix it immediately instead of searching for the “perfect” solution.

Waiting will inevitably cost time and valuable resources. Instead, on-the-spot troubleshooting allows production to continue while the new, improvised solution can be analyzed using continuous improvement techniques. You might find that what was first a temporary fix could lead to permanent positive changes. 

Lean Tip #3449 – The Rule of 1% Improvement 

Improvement is a never-ending process. There’s always something that can be improved, and there are many ways of doing so.

The Rule Of One Percent Improvement: The rule states if you improve just one per cent each day then at least three hundred sixty five improvements will have been made by your business by the end of the year. It’s about Marginal Gains and it’s like compound interest but for business results.

This means even small changes done consistently over time lead up to big results! Transforming performance may seem like an impossible task but with kaizens, it becomes much more manageable as we take continuous steps towards our goals through our teams and our people.

Lean Tip #3450 – Challenge the Status Quo

Throw out all your old fixed ideas on how to do things. Replace “sacred cows,” personal opinions, and “it’s the way we’ve always done it” with performance facts and data. Numbers are the language of improvement. Avoid the emotional traps of blaming people or making excuses that prevent you from discovering the real problem. Once you have established the new best-way of doing something, stick with it until a better way is found.


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Friday, January 26, 2024

Lean Quote: Reducing Burnout in the Workplace

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 greatest weapon against stress is our ability to choose one thought over another.  —  William James 

Stress is one of the most daunting obstacles to employee engagement in the modern workplace. Stress makes people nearly three times as likely to leave their jobs, temporarily impairs strategic thinking, and dulls creative abilities. Burnout, then, is a threat to your bottom line, one that costs the U.S. more than $300 billion a year in absenteeism, turnover, diminished productivity, and medical, legal, and insurance costs.

As managers and companies, we need to examine our employees and the environments we create for them. We need to make sure we are providing an office that fits our employees' definition of “not stressful,” not just what we think that looks like.

Increase psychological safety. If your employees perceive your workplace as a threat, then you cannot build the trust your team needs to collaborate and innovate effectively. There are three steps you can take to build psychological safety. First, make your expectations obvious by giving your employees clear goals. Second, make sure everyone feels like their voices are heard, and that everyone knows that you want their voices to be heard. You can do this by inviting people to speak up in meetings and conducting brainstorming sessions more than you impose top-down decisions. Third, develop a work environment that is both challenging and unthreatening. Let people know it’s okay to fail.

Be transparent. If your team members are confused about how their work connects to and serves both the short- and long-term company goals, they will naturally become more stressed and less productive — especially in times of uncertainty. Part of your job is to help them see the big picture, or the role they play in helping the company achieve its larger goals. While you may not be able to share everything with your team, you can provide them with the information they need to understand how their work is contributing to the company’s mission. You want to reduce the stress that accompanies ambiguity.

Give as much autonomy as you can. When possible, give your team control over how they manage their projects. Employees are 43% less likely to experience high levels of burnout when they have a choice in deciding what tasks to do, when to do them, and how much time to spend on each. To make sure someone is ready to work independently, ask them to shadow you on a task or project first, and then allowing them to practice under your supervision. During this time you can give them feedback and gauge when they will be ready to work on their own.

Create a culture of recognition. Publicly recognizing the hard work and contributions of team members decreases feelings of stress and increases feelings of connection and belonging. Research has shown that companies with high-recognition cultures perform better and have less turnover than those that don’t. This is, perhaps, because support and recognition make it easier for people to cope with the demands of work by showing them that their efforts are valued. Team meetings are a great time to call out exceptional performance. Unexpected gestures that communicate sincere appreciation can also be effective.

Decades of data have confirmed that higher employee engagement, or the strength of the mental and emotional connection an employee feels toward their workplace, has many positive benefits — including reduced stress, improved health and job satisfaction, as well as increased productivity, job retention, and profitability.