Learn From Other’s Mistakes But Don’t Forget to Make Your Own!

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We we try something new often people find out how others have done it in the past to avoid doing the same mistakes . Like in lean transformation we try to copy the path taken by the successful companies and apply tools and methods exactly the same way thinking we can save ourselves the pitfalls of the change process. We want to learn how people failed doing something and then avoid doing it ourselves thinking we are saving ourselves from the trouble. This may help us for short time but is not necessarily the best way.
Each organization, each process and people are different. We cannot expect the same results by applying what others have done. There is a need to experiment, allow failure and learn from it. People learn a whole lot from failure than from a success. Failure forces people to think, by thinking we learn by learning we improve.
By all means get out there and learn from others but don’t stop experimenting yourself. Learning from your own mistakes will make you and your team confident and successful at implementing Lean Transformation and will make you experts specifically for your processes. This knowledge cannot be build within the organization by just learning about what others are doing.

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Mission Statement: Part 2- Decoding the Mission!

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I got some good feedback on my post about Mission Statement from the Lean Community (Link to Discussion). After considering the inputs and some thinking I have slightly changed the statement to the following:

“Right the first time on time by optimizing all resources in safe environment via engaging people towards the goals of our Organization”

Writing a good mission statement is just the tip of the ice-berg. Best Mission Statement could be useless if we don’t have a mechanism to convert it in to a language that is easily understood by everyone in the organization. To achieve the Mission we should be able to know what the objectives that enable to reach our goal are. Consider the manufacturing operation, how does the above Mission Statement relate to key objectives of a manufacturing operation:

Key Performance Objectives
1. Quality: Right the first time
2. Delivery: On time
3. Productivity: Optimizing all Resources
4. Cost: Optimizing resources
5. Safety: In Safe environment
6. People: engaging people
7. Alignment: towards the goals of our Organization

Breaking the Mission into “key performance objectives” help you to understand how to affect various processes. The next step would be to figure out how to measure this performance and ensure we are on right track.

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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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Mission Statement: What is the mission of Manufacturing Operations?

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For sometime I have been trying to develop comprehensive mission statement which could be used for any manufacturing operations.

It all started with the most basic requirement  of any operation:

” Right the first on time”

This did not encompass other important aspects of business; People, Safety and business goals. So the statement was  modified the statement:

” Right the first time on time by engaging people towards business goals in safe environment”

What according to you is the mission of manufacturing operation?

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Learning : A Way to Retain Talent

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How often you have spent time and effort to hire talented people for your organization and lost them after you have invested significant amount of time training them. The fact is , however hard to believe, they leave because we lack the training….. the right kind of training. Most industrial training is about how to do the mundane tasks of a particular job. This does not improve the talent of the person nor does it create a spark of interest in a person who is inclined to be knowledge driven. For this type individuals who are creative problems solvers and strive to develop and improve themselves by taking up new challenges, learning something new is a big motivation and a stimulant for happiness. Continuous learning helps people to feel the sense of achievement which may be even harder to achieve by increase in salary.

A good organization hires the right people, a great organization trains and develops their people continually building stronger long term relationship with their employees. Training and learning is not only the means to retain the right talent but also attracts similar minded people to join the organization.

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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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Stand-Up Workstation

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Finally I made my very own stand up workstation. We put it together using the top part of an old desk which had a slide-in keyboard, rest is made of scrap metal found in the plant.I am hoping this is just the beginning that will help in changing the way I manage my standard work. I  will add other components to rearrange my dashboards and other items to operate  from one place standing in front of the  workstation. The first day was little painful standing for more than 8 hours, but I am guessing this will pass and I will get used to it. Since I have the the desktop setup on this workstation it has limited mobility, but it is good enough for my purpose.  I also have my desk and chair right next to it.The next phase is to move them away. Will post the progress and my experiences with this new setup.

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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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