The Lean Journey: Motivation gets us started but only habit can keep us going

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I am always interested in how to get people started on their lean journey and also how different cultures and companies behave, learn and progress on their journey. What I have seen working in India and here in US is that many times people get intimated by the change when you throw in all the lean jargon and fancy Japanese words. I learned about lean for more than a year at the beginning of my career without knowing that it is called “Lean”. It was just systematic application of common sense to solve problems and improve every day.

Many people start on the journey and few continue long enough to realize organization-wide transformation. Reasons may vary from place to place. The most common one is lack of commitment to continuous improvement from the top management.  Other one which may not be realized by many trying to transform the company is the change in the management from traditional to Lean management.  The biggest, and also least known, reason for not continuing is not being able to transform the mentality of the people involved.

Most people start on their lean journey because there is a desperate need. This may be increased cost, very long lead times which ultimately may lose a customer or close the whole business. This is their “Burning Platform”. This is often the motivation that gets many people started on lean journey but if they fail to transform the management to lean management and managers to lean manager, then they will go back to their old ways once the problem is solved. Burning platform is the opportunity to get into everyone’s mind because that is the time it is open for change. This change is possible by changing the habits,   one the tools to facilitate this change is Leader Standard Work. You religiously do the right thing every day till it becomes a habit.

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Pareto and Parkinson: Lean Project Management

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I got inspiration for this after reading the “4-hour Workweek” by Tim Ferriss. His advice on Productivity can be summarized by these two laws:

Pareto Law- Limit tasks to the important to shorten work time (80/20)

Parkinson Law- Shorten work time to limit tasks to the important

We have effectively used this to manage our projects in the past. The bigger the project, it is more susceptible to scope creep and also longer the duration of a project the tasks will unnecessarily  expand to fill the time available for its completion.

Our solution was to break down any big projects into multiple small projects which had a time limit of just 1 week.This forced the project managers to focus  only on the most important tasks. Also possible issues which affected the scope and cost of the project were realized much earlier and possible counter measure could be put in place. Many times the planing could reduced significantly when were similar type of small projects, the template developed for the first project could be used for subsequent projects.

These laws not only apply to project management , but also help us to be productive outside  our professional world.

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Stand-Up Workstation : After 2 Weeks

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There has been some progress with stand-up workstation experiment.  I have added few components that I manage on the wall next to the station. Above the worstation is the Mission and Key Performance Indicators for the Operations department. On the left side are three section  for Product Request, Issues, and Projects.  Each section has incoming items (lower level) which are waiting review and Active items (upper level). Right above each section is the Standard Operating procedure (under development). This helps in visually managing the activities I need to do(any paper waiting in the lower level is activity due).On the right side is the area allocated to track Metrics like Quality, Order Delivery, Cost, Productivity and Safety.

I am already feeling lot more productive at the end of the day than before. Standing up usually gets things done lot faster, maybe because you are more alert than in sitting position. At this point there are lot more things to be done, like how to visually manage leader standard work.  Other things I want to add is visual tool to deploy/ manage strategies.

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Gemba Walk: Mangement by Walking Around (MBWA)

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What is a Gemba Walk?

Gemba walk , in simple words is a form of “Management by Walking Around” (MBWA).  This is a very powerful tool as it is based on the fundamental principles of lean known as the ” 3G’s of lean ” as listed below. Gemba walk provides a first-hand unpolluted information about your Processes, Products and People.

3 G’s of Lean

Gemba – “The actual place”. This a place of actual work where the value is created

Gembutsu – “The thing”. Products or things which we are interested to improve.

Genjitsu – “The facts”. The real facts that are happening at the place of interest

I like to call Gemba walk as Management by walking around because it allows you to do just that. A 15 minutes Gemba walk has proved to be more effective in resolving flow interrupters for delivery than having hour long status meetings far away in the comfort of the office with unreliable data. When you are out there on the Gemba looking at the actual process, products and people responsible for them, there is no doubt about anything ,  no one can fabricate false information, you can interact with the process owner to resolve problems more quickly. This also helps all the Line Managers to align their priorities to solve problems for more efficient flow of the products through the value stream.

Few things to keep in mind to make this a successful tool:

- Have a clear theme and agenda for the walk

- prepare a list of questions to ask

- Setup a display board for each workstation which help process owner to answer question you will be asking

-  Have the top-most management do Gemba walk along with you at least during the initial phase, that way everyone know that we are serious about improvement

- Be disciplined never miss the gemba walk

- Make sure resources are made available to resolve issues discovered during the walk

- make sure the account abilities are clear and everyone responsible completes their task

Gemba walk  will be a good management tool as long as you use it properly. It can be used to serve various purposes. I will share more about my experiences in later posts. Till then if you have any questions or you need to know  anything  in particular about its implementation and application…. just leave a comment below.

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How do we Learn?- The process and tools of Learning

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Actually a post “Learning to Learn” by Evan Durant inspired me to write this. This topic has always intrigued me and have read my share blogs posts, books to satisfy my curiosity. I would like to share my experiences and experiments on this process and learn what others have done. I will briefly explain my philosophy and tools to slay this dragon!

The Philosophy of Learning:

Learning is not possible unless there is creative tension. Imagine a place where everyone agrees, they will never learn new things and grow. For this to be possible you need the right people and right environment. Right people are the one who questions the status quo and are not afraid constructive criticism. This is a tough team to have they will always keep you on your toes. The environment or conditions that will lead to learning  are explained more in detail in my post “The 8 Fold Path”. This is just my opinion but I believe most learning system will be composed of one or more similar building blocks.
The Tools:

Task Standard work & Leader Standard Work: We need to be able capture knowledge at process level and then link it to peoples tasks. The combination of task and leader standard work helps to achieve this. We had started to use this tools out of necessity for standardizing our tasks but learned it can be a effective learning tool when a new person joins a team or even for cross training. Task Standard work ensures all the tasks required to sustain a process are understood and captured thus providing reference point for future improvements. Leader Standard work ensures these tasks are performed by responsible individuals.In case of new person or cross training leader standard work helps the individual to do things religiously on daily basis till becomes a habit that helps him/her to do the job. The right habits helps develop right culture. Thus these tools if used properly can used to help people learn the culture of the organization. They are also good catch-ball mechanisms between the trainer and trainee.

More reading: “Leader Standard Work” , “Task Standard Work”

Gemba Walk: This is yet another catch-ball mechanism and very effective to get whole people on the team to align their thoughts and understanding. We cannot transfer what is there in our mind to somebody else’s  in an instant. We have to reinforce the idea again and again and how it implies in different scenarios till the other person understands its application and corrects any misunderstanding under the observation of the trainer. Every time the learner makes mistake the trainer is there to correct his path and realign their understanding. Several iterations of this during the gemba walks helps  everyone to learn  and align their ideas.

A3 Problem Solving: This is by far the most effective tool in teaching problem solving. It forces the learner to go through the PDCA cycle helping him to learn the systematic problem solving using scientific method. Second, the  catch-ball mechanism by which I mean every time the learner proposes a solution the trainer can send it back asking for  necessary fixes, and this cycle can go on till the best solution is reached.

Internal Training : We used to have weekly 30 min training for all the managers where anyone propose a training topic and present it. Mostly it would be one point lessons and sometimes games to show how one piece flow is better than batch. It was a fun way to learn and also a good opportunity for new managers to learn the skills of teaching in a safe environment.

Whatever you decide is your philosophy of learning or your tools, always remember to standardize the learning process so that any ineffective processes or steps can be improved or eliminated. We cannot learn the learning process without knowing what it is.

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Game Mechanics:An effective way to engage your people

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Few months back I had an opportunity to attend one our customers “Training and Supplier trade show”. The event is held annually so that all the buyers and managers get to meet all the suppliers and see their offering and collaborate to find better solutions.  They must have realised long time ago, for a event like this it is hard to make everyone work seriously with their vendors. For most people in these events it is a break from the routine, free travel at company’s expense free food and drinks! especially the free drinks :) . Working on serious issues like a cheap alternative for current service from a vendor is last thought on anyone’s mind.

But the event was not even close to this, surprisingly everyone was very seriously involved and they were enjoying it both the Company’s employees and also the vendors. The mantra for this was an ingenious way of integrating game mechanics into the purpose of the event. Concept was simple there were teams of  which consisted certain business units and randomly chosen vendors.It had very common game elements like points, leader boards and Big Prizes.Vendors had to come up with 3 points defining how they help the company through their service and products. Employees got points by going to each booth finding out what are these 3 points and remembering them. More booths you visit more points your team gets, which was continuously updated on the leader board. The winning team got an actual NASCAR race car body shell and bragging rights for the whole year. It did not matter how valuable the points are or what you will do with car body shell, everyone was motivated to do exactly what the event intended to do: Interact and know more about your vendors, find their offerings and often quest for more points led to discovery of new vendors or services.

Games have very powerful effect on motivating people. A simple but well designed game can keep people engaged and aligned towards the goal. I remember a year ago when we started a 5S reward system it were these same elements of points, leader board and a prize that kept people motivated facilitating change in effective manner.

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Lean Management – Driving force of Lean Transformation

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How many times have you successfully implemented change using lean tools only to realize, after few weeks or months, that the manager and other people  have either reverted back to the old methods or have found ways to circumvent the newly established methods.

We learned the hard way that lean transformation cannot be supported and sustained with  traditional management system

Most of the times traditional management is results driven and may not focus on the process. Thus there is no inherent  motivation for the manager to improve the process. Also when lean tools are applied  this type of management does not provide a sustainable system to integrate, improve and sustain changes with daily feedback to realign to solve problems as they arise.

The “Lean Management” provides the framework to drive the lean culture. As identified by David Mann in his book “Creating Lean Culture“, there are 4 elements that makeup the Lean Management:

1. Leader  Standard Work

2. Daily Accountability

3. Visual Controls

4. Discipline

Leader Standard Work sustains the systems integrates the changes made during the transformation process. Visual Control and Daily Accountability helps keep the process and people aligned to solve problems as they arise. The Discipline of the leader ensures that standard work is followed and the whole system works coherently.

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Leader Standard work – A bite a day keeps audit away!

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I was reading “Audit Vs. leader Standard Work” by Mark Rosenthal and I suddenly realized what potential we have created at our work place.

Over the course of the year we have grown very fond of the audits. Especially for 5S and we are developing audits  for maintaining other lean management systems put in place. So far they worked fine and actually helped us to stay on track and also creating in culture of continuous improvement. So you may be wondering why that is bad?

As Mark explains Audits are snapshot and often people will try to fool the system to be good for the audit but bad on other days when there is no audit. Now I wondered why it was not realized at our place?

The reason for this was simple , we had unknowingly incorporated that in our Gemba Walks. This ensured continuous followup of all the set systems on daily basis. This was an important move,  addressing to issues as we walk through the workstation was part of our Leader Standard Work (LSW). This kept the systems in check on day to day basis, for example an operator was informed about parts without any designated place immediately when it was seen rather then waiting to conduct the audit.

This has inspired me to think of new system where in we will no longer need audits as we will do bit of checking everyday by enabling it through LSW of responsible people.

Some things which helps to achieve this goal :

1. Try to break down big monthly tasks into smaller weekly  tasks , similarly weekly to daily tasks.

2. Use knowledge gained from issues of shop floor modify LSW to fit systems put in place to avoid these issue in future

3. Even if you have to use audits initially , make them stricter , raise the bar up as people start getting better

4. be disciplined to resolve issues  immediately rather than waiting for the next formal  audit

I am hoping to learn more by looking at audits and leader Standard work from this Perspective and ultimately be able to stay away from audits  by taking a bite a day using the Leader Standard work.

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5S- The Foundation of Lean Manufacturing

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5S is often misunderstood as just a mere housekeeping tool. Impact of having a successful 5S system is more profound than just keeping the place clean.

5S is the starting point of any lean transformation and forms a catalyst for culture of change. Due to the very visible results it makes the process of buy-in easy for both the shopfloor personnel and Management.

some of the key points why 5s forms the foundation of lean manufacturing is as follows:

  • Standardisation of process provide a stable base for incremental improvement
  • Visible results helps boost morale of the people who then take pride working in this area
  • Is an enabler of Continuous Improvement culture
  • Prepares the workplace and people for implementing other Lean tools like TPM, SMED etc.

5S implementation may sound easy but in reality it may be very complex and even more complex is how to sustain it. Not being able to sustain 5S is one of the biggest reason for failure any lean implementation project. Properly sustained 5s program helps continuously improve the workplace and shows managements commitment to the whole change process.  Leader Standard Work is one of the way to sustain 5S and new control measures developed by implementing 5S.

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A Lens to View the Transformation – Shingo Prize Model

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Often we need to see something of interest from differnt perspectives to get comprehensive understanding. The tools that allow us to see thing with different prespective is called a  “Lens”. This is very essential for a change agent involved in Transformation of a business.

Shingo Prize model offeres an excellent lens to view the transformation process. Let us first use typical Project management method as a lens. Using this you will view the transformation as different phases of the project mamngement:

  1. Initiation
  2. Planing
  3. Execution and control
  4. Closing

This will suffice if was just project management, but lean transformation goes beyond that. At strategic level we need to understand whether we have created a system which will be sustained with proper enablers in place. What most people don’t uderstand is that lean cannot be sustained if applied locally using few tools. It is has to be complete transformation of the entire system, the processes as well as the management system. Shingo prize model helps to identify what needs to be in place to strat this transformation (the cultural enablers) and then how the collective learning and implementaions of tools though out the system achive the goal of lean transformation, that is profitable business. Here are the phases of lean transformation as per Shingo Prize Model:

  1. Cultural Enablers
  2. Continuous Process Improvement
  3. Consistent Lean Enterprise Culture
  4. Business Results

If you are change agent trying to transform a business and have been wondering if you are on right track, step back look at the process using this lens.

You can read more about this at MissionModel

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