Lean Six Sigma Academy

A Factory of One

Ron Pereira — Thu, 26 Apr 2012 14:17:39 +0000

If you missed our most recent webinar called “A Factory of One“ you can watch a replay of it here.

It was excellent and I highly recommend you take the time to check it out.

It’s free to view until May 15, 2012. After that it will only be available to subscribers of Gemba Academy’s Complete Lean Package.

You can watch the entire, hour long, webinar by clicking here.

Here is a description of the webinar.

Most people spend all their time applying lean tools to external processes and systems. But what about the fundamental machine of production: you? How can you reap the benefits from applying lean concepts to your own work?

Indeed, you can apply lean principles and tools such as visual management, flow, pull, 5S, and kaizen to your individual work to improve efficiency, reduce waste, and link yourself ever more closely to customer value. While it’s true that applying lean at the individual level won’t lead to an overnight revolution in organizational performance, it can lead to success stories that make you more effective, and can get your leadership to sit up and pay attention.

Dan Markovitz will share specific strategies from his new book, A Factory of One, that will help you use lean principles to make yourself and your teams more effective.

Watch the webinar by clicking here.

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Caine’s Arcade

Ron Pereira — Mon, 16 Apr 2012 18:10:23 +0000

I second Dan in saying this may be the best 11 minutes of your day. If you want to be inspired – and smile – watch this video (click through to site if you’re reading via email or RSS). Really, folks. Please watch this. All of it.

Webinar Replay: Using SPC to Make Better Management Decisions

Ron Pereira — Tue, 27 Mar 2012 16:09:57 +0000

Update: This webinar can now only be seen by subscribers to the Complete Lean Package.

In this pre-recorded webinar, Mark Graban, author of Lean Hospitals and the upcoming book Healthcare Kaizen, showed how simple statistical process control (SPC) methods can be used by managers and leaders to make better decisions about their businesses.

Using examples from manufacturing, healthcare, and services industries, Mark illustrated the basic SPC rules and explained how to create and interpret a control chart, allowing you to spot statistically valid trends and avoid overreacting to common cause variation in your performance measures.

Click the thumbnail below to watch the webinar, which includes Q&A at the end.

No related posts.

Perseverance & PDCA

Ron Pereira — Tue, 13 Mar 2012 17:05:38 +0000

“Let us run with perseverance the race that is set before us” (Hebrews 12:1).

The ability to persevere through the tough times we experience as lean and six sigma practitioners is extremely important.

In fact, the ability to persevere through the tough times we experience as human beings is also important.

But, unfortunately, perseverance alone isn’t eough.

Not Enough

You see, in order to find success at work or home we must also continuously turn the PDCA (Plan, Do, Check, Act) wheel.

We must seek to deeply understand the problem or problems.
We must have the courage to relentlessly attack these problems knowing full well many of our countermeasures won’t work.
And once we discover a successful countermeasure we must seek to understand why it worked.

Definition of Insanity

Put another way… perseverance without PDCA is similar to the definition of insanity whereby one tries the same thing over and over expecting different results. Not only is this a painful way to live our lives… it will indeed drive a person mad!

What do you think?

Do you agree with my thinking here? Can perseverance succeed without some form of problem solving?

And what about PDCA without perseverance… can that work? What do you think?

Kanban Systems Overview Video

Ron Pereira — Mon, 05 Mar 2012 12:58:21 +0000

Here’s the first overview video from our latest course focused on Kanban Systems.

And here’s a summary document of this video in PDF format that can be downloaded and printed.

If you’re reading this via email or RSS feed you may need to click through to the website to see the video.

Finally, we’re experimenting with YouTube’s new captions system. You can use it to add subtitles of many different languages. Just click the CC button once the video starts to play in order to access the Captions menu and choose the language of your choice. You can also disable captions in this same menu.

Happy Birthday, Webinars, and Kanban

Ron Pereira — Thu, 01 Mar 2012 17:49:58 +0000

We have some exciting things going on over at Gemba Academy which, for those new to LSS Academy, is our online training partner.

Happy Birthday!

To start, Gemba Academy turns 3 years old this month! It’s been an amazing journey so far and we’re so humbled and honored to serve our customers.

To celebrate our 3rd year of being in business we’ve brought bought our extremely popular Free 34 Lean DVDs promotion.

Specifically, anyone that purchases a 6 month or 12 month online only subscription will receive all our videos on 34 Lean Training DVDs free of charge. So separately, these 34 DVDs retail for $795.

All the details for this promotion can be found here.

New Kanban Course

Without the doubt the single most requested course we’ve ever had is a more focused view on kanban systems.

As many of you know, this is a massive topic and numerous prerequisites must be in place before attempting kanban. This is why we didn’t rush to it.

With this said, I’m excited to announce that we’ve just released “phase 1″ of our Kanban Course journey. I mention phase 1 since we plan to build onto this course covering topics like heijunka is much more detail.

During this course we explain how to go about implementing both 2-Card and Signal Kanban Systems.

We did our very best to explain all the small details, often left out in the books many of have read, explaining things like how Production and Withdrawal Kanban must always work in harmony as well as what to do when that changeover time is, how should I say, less than ideal.

All the details for this Kanban Course can be found here.

Webinars

In collaboration with the Kaizen Institute and Mark Graban we’re hosting two free webinars this month. Space is limited so be sure to reserve your spot quickly!

Daily Standards for the Lean Supervisor: In this webinar, Steve Burkhalter, a Kaizen Institute Senior Consultant, will contrast the leadership paradigms of traditional supervisors and lean supervisors. He’ll define the 10 Standards of daily lean supervision and how to maintain these within your company’s Lean Operating System.
Using SPC to Make Better Management Decisions: In this webinar, Mark Graban, author of Lean Hospitals, will show how simple statistical process control (SPC) methods can be used by managers and leaders to make better decisions about their businesses.

Improving Point of Use Lid Storage at Starbucks

Ron Pereira — Tue, 31 Jan 2012 16:57:07 +0000

On a recent visit to a Starbucks inside the San Francisco airport I snapped the picture to the left. Click the image to enlarge it.

As you can see they store lids in this unit and present it close to where the “final assembly” Barista does their work.

I liked that. No walking and limited reaching meaning the waste of motion is minimal.

What I didn’t like was how the lids in the highest section were almost empty.

As such, reaching these lids would be harder since they are much deeper inside the storage unit. I couldn’t tell if there were different sizes of lids in each section. Perhaps there were.

What would you do to improve this?

If Starbucks hired you to help improve this particular point of use lid storage unit what changes would you make, if any?

10 Books Every Continuous Improvement Practitioner Should Read in 2012

Ron Pereira — Thu, 12 Jan 2012 12:30:57 +0000

I hope everyone had a safe and happy new year and that things are off to an awesome start for you and yours!

To help kick off the new year I thought I’d share a list of the 10 books I recommend all Continuous Improvement Practitioners read in 2012.

I’d also love to hear your thoughts on books you recommend.

Finally, if you purchase any of the books below after clicking the links LSS Academy will earn a small commission. This helps us pay for site maintenance and hosting.

1. The Tipping Point

This is, without a doubt, one of my all time favorite books.

And while it may not be on every “book list” for lean and six sigma practitioners… it should be!

You see, in order for any “movement” to take hold you must find a way to get the idea to tip.

This books explains how to make that happen.

Amazon’s Description:

The tipping point is that magic moment when an idea, trend, or social behavior crosses a threshold, tips, and spreads like wildfire.

Just as a single sick person can start an epidemic of the flu, so too can a small but precisely targeted push cause a fashion trend, the popularity of a new product, or a drop in the crime rate.

This widely acclaimed bestseller, in which Malcolm Gladwell explores and brilliantly illuminates the tipping point phenomenon, is already changing the way people throughout the world think about selling products and disseminating ideas.

2. Outliers

Again, this isn’t your typical continuous improvement book… but it is a fascinating read on why some people succeed and some people don’t.

I especially loved the part of the book that explains how long it takes for someone to master a skill.

For example, do you know how many times the Beatles struggled before small pub crowds before making it big? Gladwell tells the whole story.

Amazon’s Description:

In this stunning new book, Malcolm Gladwell takes us on an intellectual journey through the world of “outliers”–the best and the brightest, the most famous and the most successful. He asks the question: what makes high-achievers different?

His answer is that we pay too much attention to what successful people are like, and too little attention to where they are from: that is, their culture, their family, their generation, and the idiosyncratic experiences of their upbringing. Along the way he explains the secrets of software billionaires, what it takes to be a great soccer player, why Asians are good at math, and what made the Beatles the greatest rock band.

Brilliant and entertaining, Outliers is a landmark work that will simultaneously delight and illuminate.

3. Understanding Variation

If you work in the field of continuous improvement and haven’t read this book please do! It will change the way you approach attacking problems.

In fact, I will make the bold statement that this is the best book ever written on the topic of attacking variation through the use of control charts.

Buy 10 copies of this book and hand one to every practitioner you know. They will thank you later. I guarantee it.

Amazon’s Description:

We live in the Information Age, and much of that information comes to us in the form of numbers. But before numerical information can be useful it must be analyzed, interpreted, and assimilated.

Unfortunately, teaching the techniques for making sense of data has been neglected at all levels of our educational system. As a result, through our culture there is little appreciation of how to effectively use the volumes of data generated by both business and government. This book can remedy that situation.

Readers report that this book as changed both the way they look a data and the very form their monthly reports. It has turned arguments about the numbers into a common understanding of what needs to be done about them. These techniques and benefits have been thoroughly proven in a wide variety of settings.

Read this book and use the techniques to gain the benefits for your company.

4. Kaizen: The Key To Japan’s Competitive Success

If I was only able to own one lean or kaizen related book this would be my choice.

In fact, my father gave me a copy of this book while I was in college. So, in fact, this was the first lean related book I ever read!

Kaizen: The Key to Japan’s Competitive Success was the first kaizen related book released in the west and will leave an indelible mark on how you think about kaizen in your workplace.

Amazon’s Description:

For the professional manager or student of management, a comprehensive handbook of 16 Kaizen management practices that can be put to work. KAIZEN uses more than 100 examples in action and contains 15 corporate case studies.

5. The Toyota Way: 14 Management Principles from the World’s Greatest Manufacturer

The Toyota Way is another must read for all continuous improvement practitioners.

Dr. Liker does a fantastic job of teaching lean concepts while also mixing in stories he learned during his time studying Toyota.

One of my favorite stories is how a Toyota Engineer drove a Sienna all over America in order to better understand how to improve its performance. Talk about going to gemba!

Amazon’s Description:

In factories around the world, Toyota consistently makes the highest-quality cars with the fewest defects of any competing manufacturer, while using fewer man-hours, less on-hand inventory, and half the floor space of its competitors. The Toyota Way is the first book for a general audience that explains the management principles and business philosophy behind Toyota’s worldwide reputation for quality and reliability.

6. The Toyota Way Fieldbook

The Toyota Way Fieldbook is one of those books you will have highlighter marks and notes written throughout the book.

This book isn’t meant to be read one time… it’s meant to be absorbed and referenced again and again as you make your way through your continuous improvement journey.

Amazon’s Description:

The Toyota Way Fieldbook is a companion to the international bestseller The Toyota Way. The Toyota Way Fieldbook builds on the philosophical aspects of Toyota’s operating systems by detailing the concepts and providing practical examples for application that leaders need to bring Toyota’s success-proven practices to life in any organization. The Toyota Way Fieldbook will help other companies learn from Toyota and develop systems that fit their unique cultures.

7. Taiichi Ohno’s Workplace Management

If you ever wanted to go inside the mind of Taiichi Ohno, the chief architect of the Toyota Production System, this is the book for you.

While this is a shorter read than the others recommended in this article it will not leave you disappointed.

This is another book worthy of handing out to every lean and six sigma practitioner in your organization.

Amazon’s Description:

This classic work by the founding father of the Toyota Production System returns to print in a new translation. Ohno delivers timeless lessons on how to effectively manage the gemba actual place or work. He relates stories from across his nearly 40 years of struggle to establish the Toyota Production System as both a mindset and supporting behaviors of constant improvement. In the book s 37 chapters, Ohno covers a broad range of topics and lays out the fundamental philosophy of kaizen (continuous improvement) that has made Toyota the most successful automobile manufacturer today.

8. The Goal: A Process of Ongoing Improvement

Three words best describe this book. A true masterpiece.

I loved this book so much I not only read it multiple times… I also bought the audio book and listened to it!

In this book the late, and very great, Eli Goldratt takes us all on a fantastic Theory of Constraints (TOC) journey.

Amazon’s Description:

Written in a fast-paced thriller style, The Goal is the gripping novel which is transforming management thinking throughout the Western world. The author has been described by Fortune as a ‘guru to industry’ and by Businessweek as a ‘genius’. It is a book to recommend to your friends in industry – even to your bosses – but not to your competitors.

Alex Rogo is a harried plant manager working ever more desperately to try and improve performance. His factory is rapidly heading for disaster. So is his marriage. He has ninety days to save his plant – or it will be closed by corporate HQ, with hundreds of job losses. It takes a chance meeting with a colleague from student days – Jonah – to help him break out of conventional ways of thinking to see what needs to be done.

The story of Alex’s fight to save his plant is more than compulsive reading. It contains a serious message for all managers in industry and explains the ideas which underline the Theory of Constraints (TOC) developed by Eli Goldratt. Eliyahu M. Goldratt is an internationally recognized leader in the development of new business management concepts and systems, and acts as an educator to many of the world’s corporations. The 20th anniversary edition includes a series of detailed case study interviews by David Whitford, Editor at Large, Fortune Small Business, which explore how organizations around the world have been transformed by Eli Goldratt’s ideas.

9. Lean Hospitals: Improving Quality, Patient Safety, and Employee Satisfaction

While this book is definitely slanted towards those who work in the healthcare field there is much to gain for any lean practitioner.

Mark Graban, of Lean Blog fame, has crafted an excellent book that I highly recommend… especially if you work in the lean healthcare niche.

Amazon’s Description:

Winner of a 2009 Shingo Research and Professional Publication Prize

Drawing on his years of working with hospitals, Mark Graban explains why and how Lean can be used to improve safety, quality, and efficiency in a healthcare setting. After highlighting the benefits of Lean methods for patients, employees, physicians, and the hospital itself, he explains how Lean manufacturing staples such as Value Stream Mapping and process observation can help hospital personnel identify and eliminate waste in their own processes — effectively preventing delays for patients, reducing wasted motion for caregivers, and improving the quality of care.

Additionally, Graban describes how Standardized Work and error-proofing can prevent common hospital errors and details root cause problem-solving and daily improvement processes that can engage all personnel in systemic improvement. A unique guide for healthcare professionals, Lean Hospitals clearly elaborates the steps they can take to begin the proactive process of Lean implementation.

The book has an accompanying website with more information.

Mark Graban was quoted in a July 2010 New York Times article about lean hospitals.

10. Beyond Strategic Vision: Effective Corporate Action With Hoshin Planning

I have read many books on the topic of Hoshin Kanri and, in my humble opinion, this one is by far the best of the bunch.

So, if you’re interested in learning more about Hoshin Kanri, sometimes referred to Policy Deployment, you’ll definitely want to read this one.

Amazon’s Description:

Hoshin is a system which was developed in Japan in the 1960′s, and is a derivative of Management By Objectives (MBO). It is a Management System for determining the appropriate course of action for an organization, and effectively accomplishing the relevant actions and results. Having recognized the power of this system, Beyond Strategic Vision tailors the Hoshin system to fit the culture of North American and European organizations. It is a “how-to” guide to the Hoshin method for executives, managers, and any other professionals who must plan as part of their normal job.

And with your spirit

Ron Pereira — Tue, 03 Jan 2012 12:00:02 +0000

Roman Catholics around the word recently saw a huge change to the way Mass is celebrated.

Specifically, there were several changes to the prayers we say.

For example, prior to the change if you walked up to any Catholic and said, “The Lord be with you…” he or she would surely reply, “And also with you.”

Now, when the priest says, “The Lord be with you” we reply, “And with your spirit.”

Change is Hard

I won’t get into the reason this is a far more accurate reply… that’s not the point of this article. The point of this article is to explain how difficult change can be.

You see, we Roman Catholics are really into standardization! No matter where you attend Mass in the world the same readings are said. And, for the most part, the order of the Mass is exactly the same. As are the prayers we say.

So, needless to say, making major changes to the “Standard Work” of the Mass is hard stuff.

Cards in Pew

These changes were implemented the First Sunday of Advent (Nov 27, 2011). We all had cards available to help us. But even with the card in my hand I kept forgetting to reply, “And with your spirit.”

All of this really got me thinking about how hard changing any type of Standard Work can be.

It makes no difference if the changes are prayers said or work instructions for assembly operators. Change is hard… but sometimes necessary.

So, here are a few tips I have learned over the last month.

1. Advanced Warning

Prior to the change our parish announced it was coming. This was much better than simply dumping the change, unannounced, on us.

So, be sure to let everyone in your organization know changes to standard work are coming. This will help them prepare their minds for the change.

Also, it’s important to know that many people hate change. Any change. So, offering an advanced warning can help buffer the blow.

2. Documentation

Next, having the cards with the changes was definitely needed. Without them it would have been true chaos. We also practiced many of the prayers prior to the changes being implemented.

So, it goes without saying, that any and all changes to standard work should be thoroughly documented.

This documentation should also be used to train associates on the job (or in the pew).

3. Practice

Finally, no matter how much advanced warning is given the only way to deal with changes to standard work is to practice.

It’s been a little more than a month since these changes have been made and I am doing much better.

I still use the card for some of the longer prayers but now feel much more comfortable with the whole, “And with your spirit” side of the Mass.

What do you think?

If you’re Roman Catholic how have you dealt with the change?

And even if you aren’t Catholic how do you recommend implementing major changes to Standard Work? What would you add/subtract from my list above?

The Best of LSS Academy – 2011 Edition

Ron Pereira — Thu, 29 Dec 2011 12:00:09 +0000

Well, friends, another year has come and gone. As always, I’d like to sincerely thank each and every one of you for taking the time to visit LSS Academy.

We now have more than 16,000 subscribers which is simply mind blowing!

I remember sitting on my couch a few years ago pounding out my first blog article… never in my wildest dreams did I imagine the site would grow like it has.

But before we move onto 2012 here’s a look back to some of the more popular LSS Academy articles in 2011. Enjoy!