Archive for category Kaizen

Easier, Better, Faster, Cheaper…in that Order

Lean is deep. It’s multi-faceted. Heck, even the “simple” stuff is profound.

These characteristics, along with (or should I say, in spite of) my own denseness, are why my lean learning never plateaus. Here’s a very recent example of two experiences that refined my kaizen appreciation.

Experience 1. This week I attended and spoke at the Sixth Annual Northeast Shingo Prize conference. It was a wonderful experience. (See below for a picture of the “four bloggers.”) The conference title was, “Easier, Better, Faster, Cheaper.” Great title and great theme right? Like motherhood and apple pie. Who could ever argue with it?

Well, as many of us know, the title was derived from a Shigeo Shingo quote:

There are four purposes of improvement: easier, better, faster and cheaper.

Cool, right? Except, there’s another sentence that immediately follows – a sentence that should alter the mindset of most American allegedly “lean thinkers.”

These four goals appear in the order of priority.

Do you think that most executives would agree with that priority? I sincerely doubt it.

If we surveyed senior leaders, I would be quite confident that the order would be reversed. Unfortunately, such a hierarchy (no pun intended) does little to gain buy-in from the workforce and it is often inconsistent with the notion of respect for people. Which leads to my next recent experience.

Experience 2. (Actually this experience happened BEFORE the conference, but it works better explaining it in this order.) I was reading through the paper, “Transforming Kaizen at Toyota,” written by Koichi Shimizu from Okoyama University. This 29 page paper is undated, but I would guess it’s circa 2000. Shimizu presents a lot of information and analysis around volunteer and organized kaizen activities at Toyota.

Some take-aways:

  • Workers drive about 10% of the realized improvement and team leaders, production supervisors, engineers, etc. drive 90%. Here “realized improvement” is ostensibly around cost reduction through productivity and quality gains.
  • Workers principally engage in “voluntary kaizen” – kaizen circle activities and suggestions.
  • The purpose and effects of the voluntary kaizen, especially within Toyota’s US and European plants, are mainly around:
    • developing the (worker’s) kaizen mind and problem solving ability,
    • paying attention to quality and productivity,
    • perceiving the work-place as one’s own, and
    • developing self for promotion.

Occasionally, the worker generates a great idea around quality or working process improvement. But, the primary focus for the worker is typically around the “humanization of work. In other words, it starts with making the work EASIER. Just like Mr. Shingo said!

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Here’s a picture of the four bloggers at the NE Shingo Prize conference. From left to right, yours truly (the old guy in the group), Tim MacMahon of A Lean Journey, Dave Kasprzak of My Flexible Pencil, and Mike Wroblewski of Got Boondoggle? It was great meeting these very talented folks!

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Fun and Kaizen Team Effectiveness

Recently, I facilitated a very large kaizen team – 16 people. There were many credible warnings from folks in the weeks prior to the event. “This will be a very tough group,” “You thought the people from X were challenging, wait until you work with Y,” etc.

Pretty dire stuff.

The stakes were high, in that we were embarking on a new stage of the lean transformation. We were moving from the pilot location (and its value stream) to what we call “initial deployment” (ID). This is where we expand the roll-out typically to one additional location (sometimes another cell or line within a given site, sometimes a different site altogether) before then moving to full scale deployment.

Within ID, we wholly expect to experience technical scaling issues and human resource development challenges. It’s also a juncture in which there is a risk that people within the ID site may feel like  they are getting newly improved processes, with the associated standard work, visual controls, etc. that were developed at the pilot, jammed down their throats. This is one reason why we engage in what we call “a net change activity” to identify differences between the pilot and ID value streams and make appropriate adjustments. The activity also invariably identifies other improvement opportunities, some even within the pilot itself.

Our kaizen team environment, to say the least, was exciting and intimidating at the same time. Over the course of the week, the team ended up identifying a number of opportunities, implemented some outstanding improvements, established an excellent foundation for the initial deployment, learned how to PDCA, and had a boatload of FUN!

It’s not that fun was necessarily just an outcome. It was an input. It was an enabler.

OK. So, “fun” is relative. There’s fun at a wedding reception and then there’s fun doing kaizen. In the world of kaizen, there’s a big difference between, “I’d rather having a root canal,” and “Hey, change is hard, but there’s a lot of camaraderie and more than a few laughs. We can do this!”

Our 16 person team definitely was in the latter camp. We had a lot of laughs.

It was reflective of a spirit of humility – not so easy in this particular industry, often with some serious caste differences. The laughter was self-deprecating, defused the stress, helped folks move on when their “check” within PDCA revealed that their needed serious adjustment, facilitated candor,  fostered participation, and helped provide the team with energy to put in some pretty long hours. And no one was safe from the occasional fun-loving jab – executives, directors, managers, staff, and…me.

Related posts: Kaizen and Chemistry, Of Team Size, Social Loafing and Lack of Direction

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These Are Some of My Favorite (Improvement) Things

It wasn’t quite a Von Trapp family moment, but it certainly was a good lean moment. During a kaizen report-out, an associate was sharing several improvement ideas. You know the form reflecting the problem, action taken, impact and a before and after characterization of the situation? But, her introduction to her portion of the presentation was a little bit different than what I have grown accustomed to.

She started by saying, “This is my favorite improvement…” It resonated with engagement, empowerment and satisfaction. Her preamble grabbed the audience’s attention.

She and her teammates had accomplished great things in the areas of productivity, ergonomics, lead time reduction and the like. Along with that, they necessarily addressed a bunch of issues that routinely caused frustration for the workers within the target process. Things that got in the way of performing their tasks successfully.  Things that kept them from feeling like they were winning.

Her favorite improvement? It was one that enabled her and her teammates to quickly identify abnormal conditions and provide the insight necessary to knock down the root cause(s). She was looking forward to something that would further enable continuous improvement, now and in the future!

The plant manager and I chatted a bit after the conclusion of the report-out. Our mutual favorite thing was…the favorite thing. It was a “thing” that reflected much of the core of a kaizen culture.

Related post: Stretch, Don’t Break – 5 ways to grow your people

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How to Avoid Kaizen Event Malpractice

I recently conducted a free one hour webinar on the subject of kaizen event malpractice, its causes, effects and how to avoid them. More positively, the topic was largely on how to side-step the snares of tool-driven kaizen, how to securely apply, grow into and sustain system-driven kaizen and ultimately set the foundation for principle-driven kaizen.

The webinar was graciously hosted by Society of Manufacturing Engineer’s Chapter 7 from Hartford, CT with the assistance of SME National. The SME webinar library link is right HERE if you would like to view the slides and listen to the audio.

By the way, my less than clinical definition of kaizen event malpractice is the “dereliction of duty due to negligence or incompetence by a leader, practitioner or organization.” Malpractice has a number of effects, including the following:

  • poor linkage to strategic and value stream imperatives
  • little or no measurable business impact
  • unsustainable results
  • unfavorable employee experience
  • limited organizational learning and growth, and an
  • insufficient foundation for daily kaizen.

I hope the webinar adds value for those who access the library.

In conjunction with SME National, I’ll be conducting a three-part webinar series on kaizen in October. Please refer to SME Webinar Central under the October 19 and 21 offerings.

Related posts: The Post-Value Stream Analysis Hangover, There Is No Kaizen Bus Stop!

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Kaizen and Chemistry

I recently experienced  the pain associated with coaching a team with poor chemistry. It was a kaizen event team, so the pain was finite. But there are team formulation lessons learned – whether it be a kaizen event team or any other continuous improvement oriented team, kaizen circle activity teams, mini-kaizen event teams, project teams, etc.

Teams need to be built around the mission, not the other way around. So, for example, when selecting kaizen event teams, our criteria should encompass a number of things. At the risk of being way too brief and broad brushed:

  • Representation. I usually like the “1/3 rule” – roughly a third of the members from the target process, 1/3 from upstream and downstream of that process and a 1/3 “fresh eyes.” We also need to ensure that representation includes more than a couple of folks who actually DO the work within the target process, etc. Keep the team multi-level and avoid putting the manager of the target process in the team leader role (and sometimes on the team at all).
  • Size. 6 to 8 folks is a pretty good rule of thumb. Less than that is fine if the scope is really heavy on analysis (i.e., kanban sizing), otherwise we most likely need to reduce the scope or expand the duration of the event or activity. More than 8 people and we risk losing team effectiveness.  In such a situation we should be thinking about sub-team strategies.
  • Technical competencies. A team should include folks who know the technical aspects of the target process. We also need at least several people, including the team leader, who have a good measure of kaizen expertise (process, forms, etc.).
  • Core competencies. Teams should be selected such that there is a good nucleus of work habits, attitudes and behaviors that are conducive to team effectiveness – for example, group facilitation, change leadership and self-management.
But, What About Team chemistry?!?

Chemistry is critical and, at the same time, a elusive. It’s something that we often “feel” our way through. Much of the time though, it really is not considered in an explicit way.

We’re going to get a little scientific here, but know that this is just to provide some insight into things we should be considering when selecting a team for continuous improvement activities. I’m going to refer to the DISC model of behavior, mostly because I think that it’s pretty straightforward…and I am familiar with it (but NO expert) .

The DISC behavioral model is based upon the work of the late psychologist, William Moulton Marston and provides insight into people’s work styles (within given situations). Again, basic knowledge of the model  and an understanding of different styles can be helpful when we consider how to optimize team chemistry, or at least try to avoid BAD chemistry, for a given team. I am NOT proposing that we have team candidates or teams take one or more of the DISC assessment tools that are on the market.

So, what does DISC stand for? It’s an acronym for a four-dimensional model with the following “pure” dimensions. No surprise, most people are usually a combination of dimensions. For example, a high D, low C.

  • Dominance. High D’s try to shape the environment by overcoming challenges. They generally seek to get immediate results, cause action, accept challenges, make quick decisions, take authority, solve problems, etc. They desire power and authority, prestige and challenges, opportunities for individual accomplishments and direct answers. They need others who are more likely to weigh pros and cons, calculate risks, use caution, research facts and the like.
  • Influence. I’s shape the environment through influence and persuasion. Their tendencies include networking, making a favorable impression, being articulate and creating a motivational environment. I’s like popularity and social recognition, freedom of expression and positive feedback. They can use the help of others who concentrate on the task, seek facts, speak directly and take a logical approach.
  • Steadiness. High S people achieve stability by supporting and cooperating with others to achieve goals. They typically perform in a predictable and consistent manner, demonstrate patience, help others and show loyalty. S’s desire an environment that includes maintenance of the status quo, consistency and predictable routines and clear goals and expectations.   S people need others who react quickly to unexpected change, stretch toward the challenge of an accepted task, become involved in more than one thing, apply pressure to others, etc.
  • Conscientiousness. C folks work conscientiously to ensure quality and accuracy. They tend to follow key directives and standards, concentrate on key details, think analytically, weigh pros and cons and check for accuracy. They like environments that have clearly defined goals and performance expectation, policies and SOP’s and, of course, value quality and accuracy. They benefit from others who delegate important tasks, make quick decisions and move toward action and use policies only as guidelines.

Now, of course people can have different styles in different environments and if stressed they can modify their styles. For example, stress a high C and they can move into high D territory, stress a high D and well, they can become more D (that can be scary), stress a high I and they can move toward the C quadrant. As a team leader or facilitator, inducing the right stress can be a useful strategy to improve team effectiveness.

A Quick Test for You

So, given the characterization of the DISC styles, take a look at the two team DISC “circles”  (A and B) and reflect on which team, all things being equal, would be more effective kaizeners. Each of the dots represent a team member. The star represents the team leader.

Now reflect on some your past teams. Is there anything that you would have done differently to improve the chemistry? Different team member selection? Perhaps induced more or less stress on the team?

Just trying to get you to think…

Related posts: Of Team Size, Social Loafing and Lack of Direction, Kaizen Event Team Selection – No Yo-Yos Needed


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Ode to the 3X3 Inch Post-it® Note

Often, people jokingly accuse me of owning stock in 3M. Why? Because I tend to use and coach others to use lots of Post-it® notes. I do have an affinity for the 3X3 inch variety, not because I am a 3M stockholder, but because the ubiquitous notes are such an effective tool for kaizen.

Kaizen is largely about capturing and understanding the current state and the related issues, problems, root causes and opportunities. Kaizen is also about the flow of the kaizeners’ improvement ideas – sharing, communicating, building on them, adjusting, organizing, prioritizing, assigning and executing them. Post-it® notes facilitate all that.

The notes are visual, colorful (colors should mean something), adjustable, movable, scrappable (low cost, easy to create a new one) and tactile things. These characteristics make it easy to get people started – get people writing, talking, moving, sharing, debating, etc.

Post-it® notes do not engender the same fear that often accompanies the more permanent pen or even pencil on a flip chart, plotter/kraft paper, etc. The notes also avoid the hypnotic and less than collaborative effects of the computer around which a bunch of folks try to gather (if you’re lucky it’s an LCD projector) while one person controls the keyboard and mouse.

Here’s a short list of Post-it® note applications:

  • process mapping
  • value stream analysis
  • product family analysis matrix
  • Gantt charts
  • plus/deltas
  • set-up reduction analysis
  • countermeasure prioritization
  • affinity exercises
  • failure modes and effects analysis
  • cause and effect diagrams
  • layout analysis

So, I wrote a really lame ode to the 3X3 Post-it® note…because I could (sort of). Don’t worry, I won’t quit my day job.

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Oh noble 3X3 Post-it® note, I am utterly lost without thee.

You enable team members to think and engage, worry free.

Your portability and stick allow a helpful lack of permanence,

The better to help us storm, “affinitize,” prioritize and make sense.

Your hue can mean “process” or “kaizen burst,” whatever we please,

When a flow chart needs a diamond, we simply spin you 45 degrees.

Our scissors work you into a triangle if a V.S. map has a queue,

When you are side-by-side (continuous flow), truly we love you.

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Yes, the ode is lame…but, you’ve got to love those little 3X3 Post-it® notes.

Related post: Plus Delta – The Kaizen Team’s Sunrise Reflection

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Time Observations – without Rigor, It’s Just Industrial Tourism

It happens way too often. Folks who are ostensibly conducting time observations frequently:

          • don’t appreciate the full importance of the exercise,
          • are not properly trained in how to conduct time observation methods (and the the related spaghetti charts, percent load charts and standard ops forms), and/or
          • are  just too lazy to do a thorough job.

The first two conditions are more straightforward in nature, the last, well…that’s a behavioral issue.  In any event, insufficient rigor will hamstring the effort to identify waste within a given process. A prior Gemba Tales post, Time Observations – 10 Common Mistakes, covers a lot of relevant ground here.

Lack of rigor and technical know-how can yield some very bad things – not the least of which are marginally useful time observations. This means that individuals and teams can come up with a stilted understanding of the studied process, miss or incorrectly identify the waste and opportunities, develop a less than least way post-kaizen future state standard work or…even worse, create new standard work that is going to go through tremendous adjustment during the PDCA process because it does not square with reality. Think “rework ” here.

So, what drives me absolutely crazy? Lazy observers! [By the way, here we assume that the time observation is worth doing in the first place (right scope, worthy target,  appropriate tool, etc.)]

We cannot be proponents of industrial tourism. Time observations require hard work and a good dose of stamina.

Hey, stopwatches are much more difficult to operate than one would think and breaking down the target process into the smallest observable elements is a pain in the neck. Observing multiple cycles, so necessary to getting a handle on variation (and thus opportunity), means more time on your feet, more writing and attention firmly directed on a process which may be as exciting as watching paint dry…in perhaps extreme heat, cold, noise, whatever. Following the operator or worker EVERYWHERE can also be a drag. And observing a process that has varied work content based upon different factors (such as warehouse picks from high bay versus low bay locations)  … can make it even more maddening.

My answer? Suck it up! Grind it out! Man-up (not really politically correct, but you know what I mean)!

It’s not that I am without empathy. I have personally conducted countless time observations of cycles that were many hours in duration, sported crazy variation and permutations, etc. It was at times, very, very painful. But, you really can’t get the proper insight into the waste and opportunities within a process without such a personal investment, and without going to the gemba. In fact, genchi genbutsu, “go and see for yourself” …and help facilitate that seeing with the rigorous application of a time observation form.

Don’t be a tourist! You owe an A-plus effort to yourself and most importantly, in the spirit of humility and respect for the individual, you owe it to the other stakeholders – the person(s) that you observe,  teammates, customer, etc. You must pragmatically conduct the best time observations you possibly can.

What do you think? Am I too demanding here?

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Of Team Size, Social Loafing and Lack of Direction

Maximilian Ringelmann was a 19th century French agricultural engineer. I’m guessing there’s not too many of those around right now – both from the engineering discipline and  country of origin perspective. Anyway, Ringelmann discovered that as more folks pulled on a rope, more force is exerted. However, the increase on the force is NOT commensurate. Maximilian measured a type of “social loafing” – the individual, per capita effort lessens as people are added.

As we select teams for continuous improvement activity, we must be mindful of the team size. Large teams, more than eight or so, increase the probability of two types of team muda: 1) social loafing, and 2) lack of direction. Social loafing, or the Ringelmann effect, reflects the inclination of participants to slack and hide…because they can.

If you can’t feed a team with two pizzas, the size of the team is too large. – Jeff Bezos, Chairman, CEO and Founder of Amazon.com

Lack of direction can befall team members who outstrip, because of sheer number or perhaps industriousness, the aligning and facilitating capabilities of team leaders and coaches. (Here, we’re not talking about problems that are generated by ineffective team leaders and facilitators.) We know that kaizen activity – the identification of opportunities, the countermeasures identified and assigned, the learnings and adjustments that occur throughout the trystorming process, etc. can make the process a little less than orderly and predictable. Added to that chaos factor, if the team is too large, team members are  more likely to experience the waste of:

  • Waiting. Nothing like hanging around for someone to assign another task for you after you just knocked off a countermeasure.
  • Over-processing and over-production. Virtually all participants want to do value-added work. So, if there is an absence of direction (and alignment), there’s a decent chance they’ll do something, perhaps more than is required (scope creep!!) or do it prematurely – like developing visual controls before the “system” is defined, which can lead to…
  • Defects. Redoing stuff when it’s not part of the normal PDCA cycle is demoralizing. Sometimes it does not require rework, but rather scrapping – like when two people or sub-teams end up doing duplicate work. Not good.
  • Opportunity. Well executed kaizen is an opportunity for folks to improve the business. It’s also equally about improving the worker’s PDCA skill-sets and developing a lean culture. When teams are too large and they suffer the above described dynamics, we end up squandering these transformative opportunities. We then give people a good reason to call into question our competency and credibility as lean leaders.

So, how do we avoid the Ringelmann effect and the lack of direction trap? First, don’t pick a team that is too large… and always employ effective pre-planning (inclusive of clarity in scope, measurable targets, best practice team selection, required pre-work, a solid initial strategy, etc.), proven work strategies (prioritization of countermeasures, assignment, frequent status checks, etc.), promote and enforce proper team behaviors (focus, shared leadership, candor, bias for action, etc.), all while empowering the team members to figure out much of the “how” (as long as it’s consistent with lean principles) and providing them with the necessary encouragement, training and resources.

When a large team is required either by virtue of the scope/work that needs to be done or the need for multi-level and cross-functional representation, then (after you’ve decided that you can’t reduce the scope), consider the opportunities for sub-teams, load up the team with folks who have strong kaizen experience, ensure that you’ve got an ace team leader and facilitator and make sure that you’ve done a heck of a pre-planning job.

I’m sure I missed some things. What do you think?

Related post: Kaizen Event Team Selection – No Yo-Yos Needed

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Kaizen in the Laundry Room…and My Domestic Shortcomings

Kaizen opportunities are often best identified (and done) by those who do the work. This is critical if you’re trying to create and sustain a kaizen culture. That said, I usually try to avoid much in the way of lean implementation within my house and amongst my family. Not that I really enjoy all of the typical familial chaos and related muda, but, as Clint Eastwood’s Dirty Harry once said, “a man’s got to know his limitations.”

Now, my wife is the predominant laundry person in our house. Yes, I know what you’re thinking and I could lie and say it’s not like that. Sometimes I’ll do some loads, sometimes my three kids…but, that’s an abnormal condition! And, I really don’t want to talk about folding laundry. Really guilty there.

Today, Mother’s Day, my wife mentioned that having the dryer door hung on the left side of the dryer was a pain in the neck. I looked at it, with newly opened eyes, and could instantly understand the waste of motion that the door’s orientation induced. You have to remove the wet laundry from the washing machine and then lift it OVER the dryer door and THEN place it inside the dryer. Meanwhile wet socks are hitting the deck and accumulating dog hair and horse hair (no, there’s no horse inside the house). Wonderful!

I’ve had to endure that same waste, but I just turned my brain off and assumed that doing laundry was a pain the neck, because it was …a pain in the neck. If I was in lean coach or sensei mode, this would have been so obvious! Pretty lame on my part. I’ve become a domestic “concrete head.”

So, I quickly took my wife’s suggestion (no formal suggestion board here) and switched the door. Daily kaizen (at least the first one) in the laundry room! Less than 10 minutes to make it happen. Glad she’s the brains in (and heart and soul of) the family.

Now that I have shared this little story with you, I can’t help but thinking that I may be considered the new Bruce Hamilton of laundry. During Bruce’s hugely popular Toast Kaizen video, specifically the pre-kaizen condition, he’s waiting for the toast to toast, while the dirty dishes just sit there in the sink. The video observers (especially the females) often voice their displeasure with such a blatant display of sloth. Of course, Bruce gets his act together in the post-kaizen condition (here we won’t discuss the hygiene opportunities). I just want you to know – I’m a good dish guy! But, I definitely need to carry more of the load (no pun intended) on the laundry front.

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Kaizen Principle: Bias for Action

Several days ago, during a health care value stream analysis, I was impressed with the team’s bias for action. Now we know that value stream mapping is typically a “paper” activity, but it was refreshing to see that one of the future state’s kaizen bursts, identified as a “just-do-it,” couldn’t wait. The team completed the just-do-it right before the wrap-up presentation. Outstanding!

Kaizen is founded on certain principles, one of which is a bias for action. This bias for action is largely a behavioral thing, but it can be facilitated by effective coaching, formal training, and the application of lean management systems and related visual controls that should absolutely scream for action.

Of course, it’s worth mentioning my “short list” of kaizen principles (see the Kaizen Event Fieldbook), because I think we need to have a holistic perspective and because together they should drive the right kind of bias for action. I call this my 10 + 1 list. I’m pretty sure that other lean practitioners can make some  great arguments for a few more, but I wanted to keep the list relatively short.

  1. Think PDCA and SDCA, the basic scientific methods.
  2. Go to the gemba; observe and document reality.
  3. Ask “why?” five times to identify root causes.
  4. Be dissatisfied with the status quo.
  5. Kaizen what matters.
  6. Have a bias for action.
  7. Frequent, small incremental improvements drive big, sustainable improvements.
  8. Be like MacGyver; use creativity before capital.
  9. Kaizen is everyone’s job.
  10. No transformation without transformation leadership.

Plus – Do everything with humility and respect for the individual.

The combined dissatisfaction with the status quo (eyes for waste  “see” the current state and the ideal state) and the existence of explicit performance gaps that are targeted for closure (kaizen what matters) should be unbearable enough to drive action. And, our action should be focused on appropriately and economically (MacGyver was a creative cheapskate) addressing the root causes (5 why’s and PDCA thinking) and then sustaining the performance (SDCA).

So, I’ll leave you with another bias for action story, surprisingly also within a value stream analysis backdrop. Tony, the plant manager, was participating in a combined value stream analysis/plant lay-out/3P activity for a brand new line. As we developed pro forma standard work and were doing table top and plant floor simulations applying, among other things continuous flow, he had a eureka moment. Actually, I noticed that he was becoming quite agitated and then…he disappeared. Over an hour later, Tony returned. He informed the team that he couldn’t stand it when he realized that the same principles needed to be applied to existing lines. So, right away, he made sure that the other lines (granted, without standard work at the time) stop their evil batch and queue ways and go to single piece flow. By the next day, the old lines had demonstrated an 18% productivity improvement (and yes, this was sustained). Now, that’s bias for action!

Related posts: Ready! Fire! Aim!…Maybe, We Should Have REALLY Simulated First!?, Kaizen Principle: Be Like MacGyver, Use Creativity before Capital!

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