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10,000 Hours of Practice

10,000 hours. That’s precisely how long you need to practice something before you can even think about calling yourself an expert.

Well, at least this is what Malcolm Gladwell claims in his newest book Outliers, which I must say is one of the most fascinating books I’ve ever encountered.

The Story of Success

Outliers is all about what makes people great. But it’s not your typical book that rambles on about if you believe it you can achieve it. No, you won’t read anything like that.

Instead, Gladwell explains why things such as the month you were born may very well explain why most NHL players made it to the big leagues. He also explains why Chinese children dominate American children when it comes to mathematics.

10,000 Hours of Practice

But the thing that really stuck with me, and I’d to share with you now, is how Gladwell hypothesizes that it takes – on average – 10,000 hours of practice to master a skill.

Take Bill Gates. Did you know that the young Bill Gates spent more than 10,000 hours programming computers before starting Microsoft?

How about those lads from England… you know the Beatles? I bet you didn’t know they were quite terrible before having the opportunity to perform as much as five hours a night seven days a week in Hamburg, Germany before making it big.

Sure Gates and the Beatles had talent. But they also worked extremely hard. You see, it seems they practiced their way to the top.

What about Continuous Improvement?

So I couldn’t help but wonder if this 10,000 hour rule applied to those of us “practicing” continuous improvement.

To get in 10,000 hours of practice this really means spending approximately:

  • 4 hours a day;
  • 5 days per week;
  • Over a span of 10 years practicing your trade.

What do you think? Is there anything to this 10,000 hour rule? If not, are you willing to prove the hypothesis wrong?

You’re Late. What Do you Say?

It’s 7:58 AM and beads of sweat are forming on your forehead. Your pulse rate is increasing as you grip your steering wheel tightly. And to make matters worse… you forgot your mobile phone at home.

In 2 minutes you will officially be late for an extremely important meeting with your new boss and a group of customers. Oh, and these customers are visiting to discuss the poor customer service they claim your company has provided them.

The reason you’re late is not your fault. There was a major traffic accident which created a parking lot for more than one hour. The most frustrating thing is you left home extra early due to the importance of this meeting.

You finally walk into the meeting at 8:27 AM. You’re close to 30 minutes late and your new boss does not look pleased… nor do your customers.

What would you say?

The Complete Meaning of Shitsuke

There are some Westerners (Americans, Europeans, etc.) who get all bothered when lean folks use too many Japanese terms.

So these people go on about how it’s “Policy Deployment” and not “Hoshin Kanri” or it’s “Continuous Improvement” instead of “Kaizen.”

My personal opinion, if I may be so blunt, is these people lack humility. You see if it weren’t for these Japanese words – or ideas – we may still be waxing poetic about the merits of mass production.

Defining Shitsuke

Along these lines… I recently learned a lot more about a Japanese word I thought I understood. The word is shitsuke and is most commonly referenced as the 5th S in 5S. This final S typically stands for self-discipline or sustain.

Well, after exchanging a few emails with my good friend – Brad Schmidt of Gemba Research who lives in Japan and speaks the language as good as the locals – I came to realize that referring to shitsuke as self-discipline or sustain is only partially correct.

Spare the rod, spoil the child

You see, there is another meaning to the word shitsuke… and that meaning has a lot more to do with disciplining others, such as poorly behaving children, than it does with self-discipline or sustainability.

Here is how Brad put it.

When we first do 5S we do the first shitsuke which has the element of “force” in it. That’s to make sure people don’t stray from the truth. After you do the first shitsuke it then becomes the second shitsuke (self-discipline) which is more a state of being.

Be Humble

So, the next time you hear someone crying about all the Japanese words ask them if they really understand what the final S – in 5S – stands for.

Chances are they may only be partially correct… in which case you have the perfect opportunity to explain the merits of attempting to truly understand the incredible wisdom behind the Japanese words we so often take for granted.

What do you think?

Are you with me on accepting all the Japanese words?  Or do you feel like scratching your eyes out when your lean buddy talks about going to gemba?  And be honest… we’re all friends here.  ;-)

Free Introduction to Lean Video

Here is part one of our first Gemba Academy video. To see the complete and full screen version – in high definition – please visit our main site. Stay tuned for more free videos in the coming weeks.

Smiling, Laughing, and Blow-out Diapers

A friend, who’ll stay nameless since it involves a family member of his, recently told the story of how his 8 month old child threw-up on him, smiled, laughed and then had a blow-out diaper.

How’s that for imagery?

Well, my friend went on to say how he learned a valuable lesson from his child’s happy response to adversity.

Now I know the imagery of this story is less than appealing, especially to those of you without kids. But, this story really does teach us grown-ups a valuable lesson if you ask me.

He Smiled

My friend’s child obviously felt bad or they wouldn’t have been throwing up… yet they smiled.  So no matter how bad your day, week, month, or year has been try to smile more. It can’t hurt.

He Laughed

Likewise even though this poor child’s tummy obviously felt terrible… they looked up at their Daddy and laughed.

In other words, quit being so serious all the time. When you’re running your next kaizen event or teaching your next class or spending time with your family… loosen up and laugh. It’s not so hard.  Oh, and it’ll also help you smile more.

Don’t Worry

And, no, I won’t attempt to tie in how the blow-out diaper can help us be better people.

But I will say that the next time life throws you some lemons perhaps you can replay this story in your mind as you twist those face muscles of yours ever so slightly… and smile.

Come on. Let’s try it.  Smile. Come on… you can do it.  Now give me a little smile.  That’s better. Now laugh. See? It works doesn’t it?

Gemba Academy: Improvement Learning, Improved

Let me start with three words: passionate, ecstatic and enthralled.

  • Passionate is the perfect word to describe how I feel about continuous improvement.
  • While ecstatic best describes my joy at being able to share some exciting news with you.
  • Finally, enthralled is how I feel when collaborating in a mode of creative flow.

What am I going on about?

Allow me to explain.

You see I, along with two of my favorite people in the whole wide lean world (Jon Miller of Gemba Panta Rei and Kevin Meyer of Evolving Excellence), have been extremely busy creating what we feel will become the best continuous improvement learning system available.

We’re calling it Gemba Academy.

What is Gemba Academy?

Before explaining what Gemba Academy is, let me go out on a limb and make three assumptions about you:

  • You are sick and tired of training presentations full of boring text and bullet points.
  • You are not a fan of fuzzy PowerPoint presentations converted to Flash and thrown up on the Internet.
  • You are not looking forward to sitting through that next 100-slide training session.

Well, let’s just say we’re with you. As such, at Gemba Academy, were committed to the following:

  • Crystal clear high definition videos distributed on an advanced network of servers that span the globe. So, no matter if you live in Dallas, Texas or Mombasa, Kenya you will be able to watch, interact and learn right along with us.
  • Content created by active practitioners that is continuously improved and added to. We will most definitely practice what we preach.
  • Our pricing and business model is simply unbeatable. Let’s just say some people spend more every day on fancy coffee.

Simply put, Gemba Academy is where web 2.0 meets continuous improvement learning.

Gemba Academy officially launches in March 2009. But until then, you can get sneak peak at what we’ve been up to by visiting our main site at: http://gembaacademy.com.

Genchi Genbutsu: Do You Really Understand It?

“Data is of course important in manufacturing, but I place the greatest emphasis on facts.” - Taiichi Ohno

If you’ve read this blog – or really any other lean related publication – you’ve likely heard the phrase genchi genbutsu used many times.

Jon Miller – who is fluent in Japanese – recently corrected me and told me that genchi genbutsu literally means “actual place, actual thing.” The most popular definition seems to be that genchi genbutsu means to go and see with your own eyes at the place the work is done.

Definitions aside, I wonder how many people really understand what this lean philosophy truly means. Most seem to think it means to visit the gemba, or the place the work is done, when something needs addressed.

And I suppose it does. But it’s much more than this.

Meet Mr. Yuji Yokoya

In chapter 12 of Jeffrey Liker’s must read book The Toyota Way we meet Yuji Yokoya who was the chief engineer for the 2004 Toyota Sienna redesign.

Since Mr. Yokoya had never worked on a vehicle destined for the North American and parts of the South American market he asked his superiors if he could go to gemba to learn.

They approved… and boy did he ever go!

You see, Mr. Yokoya set off to drive a Sienna in all 50 American states as well as all 13 provinces in Canada. He also spent some time on the streets of Mexico.

What did he learn?

During his travels Mr. Yokoya learned many things, including:

  • The roads in Canada are very different, especially the high crowns in the middle of the road, probably meant to deal with the massive amounts of snow they get.
  • He learned that the winds in Mississippi are vicious and that, if not properly designed, the Sienna would be extremely unstable.
  • He also learned a valuable lesson about cup holders. Yes, cup holders. You see, in Japan people rarely eat or drink in their vehicles… but in the West Mr. Yokoya learned that eating and drinking in the car are very common.  So, the 2004 Sienna would soon come equipped with 14 cup holders as well as a little tray to place your Big Mac and fries.

Surveys and Focus Groups?

Some skeptics will say Mr. Yokoya could have learned some of this by sending out surveys and having focus groups share information.

Me, I am not so sure. I mean Mr. Yokoya felt the roads, he felt the wind, and he saw with his own eyes how we like to cram our faces with food while talking on the cell phone and drinking our coffee.

Now that’s priceless (and a little scary).

What do you think?

What does Genchi Genbutsu mean to you?  Do you see it practiced where you work?

Is Pottery Barn Lean?

We’ve had the same couch for about 8 years. I love it. It’s one of those huge sectionals with the “captain’s chair” in the middle.

I’ve watched my Buckeyes win a National Championship while sitting on this couch.

I’ve also held and played with all my children from the moment they each came into this world on this very couch.

So, yeah, I’m connected to this couch in a strong way. But, alas, time has worn on my poor couch and its days are coming to an end.

Pottery Barn Here We Come

As such, my wife has recently convinced me that the time was right to buy a new one. So, after some shopping we decided on a nice three piece set from Pottery Barn. I’m still in shock as to how much we paid… but hey, that’s another article in its own.

But here’s the thing. This couch will be custom made. We picked the style, fabric, color, etc. This is pretty lean if you ask me. I mean we built exactly what we wanted.

Say What?

Then I got the shock of the day. The nice Pottery Barn lady told us that the lead-time for this couch was 2 months! Yes, that’s right 2 freaking months!

So, as we were leaving the store I kept mumbling under my breath. Part of the mumbling was likely due to the shock I was in for spending so much… but the majority of the shock was likely due to the massive lead-time.

Well, being the excellent spouse she is, my wife attempted to tell me how she was surprised at my reaction.

She challenged with me with a question… she asked me isn’t their approach the lean way? Her rationale was that we – the customer – are getting exactly what we want. She also said that it would seem that Pottery Barn will not have to hold lots on finished goods inventory since they are making to order.

Let the Conversation Begin

We commenced to have an excellent discussion on these comments of hers. But rather than me replaying our conversation I’d like to hear your thoughts.

So, what do you think.  Is Pottery Barn lean?

7 Ways to Reduce Costs

If you work for a company that doesn’t need to cut costs you can ignore this article.

If, however, your company needs to reduce costs now more than ever it’s my hope this short article may help you along the way.

And while the ideas I’ll list are not revolutionary or new… chances are your company is not practicing all of them in which case opportunity exists! Let’s get started.

1. Print on both sides of paper

Paper is not cheap… in fact if you work in a big company I bet you spend thousands and thousands on it. So, instead of printing on one side of the paper use both sides. In some cases this isn’t practical… but in many cases it is.

2. Stop printing all your emails in color!

Next, challenge your workforces to stop printing emails as if life will stop if they don’t. And please stop using the color printer! I once visited a plant that controlled this by placing the printer by the managing director’s desk to control this. This may be a bit more command and control for many… but it worked!

3. Re-fill ink cartridges

The ink cartridges in those printers you have are e-x-p-e-n-s-i-v-e. So, instead of ordering new cartridges you may look into getting them re-filled. There are companies dedicated to this and from my experience the quality of their work is beyond excellent.

4. Try video conferencing

Instead of paying hundreds, maybe more, for an airplane ticket to that one day meeting why not utilize video or web conferencing instead? You can share files and collaborate very well these days with applications like Webex.

5. Use Skype

Skype is the bomb and will save your company lots of money on phone bills, especially if you make frequent long distance calls within your company.

6. Close the doors for a week

If things are really bad and it’s looking like layoffs are imminent you may try to close the doors for a week or more while asking employees to use vacation time. Sure this isn’t exactly fun for the employee… but it’s better than the alternative!

7. Frequent Flier Miles

OK, how about this heretical idea. If you fly a lot for your company and they pay for your plane tickets while you rack up the frequent flier miles… how about asking employees to use these miles for future business trips? Perhaps the employee creates a separate frequent flier program for all business trips.

Now, some will say their company “owes” them these miles for being away from their family, etc. Me, I don’t buy this. If you don’t like to travel you are always free to find another job that doesn’t require it.

You know, some place like Burger King where they do it your way!

What do you think?

What do you think of my list? Especially number 7? Can you think of any other ideas for how you can help your company save money in these difficult times?

7 Practical Ways to Respect People

How many times have you heard lean advocates ramble on about how respecting people is a key tenet of the vaunted Toyota Production System? I can’t tell you how many times I’ve heard this AND written it myself here on LSS Academy.

And while it’s true… respecting people is mandatory…what does this really mean?

How exactly do you respect people? It may sound like a simple question but I contend it’s anything but simple.

With this said, I hope to share some of my thoughts on some practical things we can all do starting today to respect people no matter if our job title is Senior Vice President or Mom.

1. Look at people when they talk to you

Have you ever been asked to come to someone’s big office for a meeting only to find them checking their Blackberry or email more than actually listening to you? This is NOT respecting people.

So, the next time you engage in a conversation – even a short one at the water cooler – look the person in the eyes when they’re speaking to you. If this means closing the lid of your laptop or putting your Crackberry in your desk drawer with the ringer and vibrate function turned off… do it.

2. Listen. Really Listen.

And as you’re looking the person in the eyes listen to them. Really listen. Often times this requires you to say a few things back that actually contain some substance.

3. Don’t always agree

Some think that to be respectful you can never disagree. This is ridiculous. My old boss at Nokia used to tell his management team that if all 8 of us agreed he had 7 too many people in the room. So true.

4. Don’t simply disagree to justify your existence

With this said, don’t attempt to always find at least one thing to disagree on in attempts to somehow feel like you’re justifying your existence.

If you agree with a point and can’t add anything to it… just say something like, “Sounds great. You’ve obviously done your homework. Let me know if I can help.”

5. Engage the Gemba

Another favorite we lean practitioners like to talk about is genchi genbutsu, which literally means to go to the place the work is done to see with your own eyes.

There are many benefits to this… but one that doesn’t get enough press, in my opinion, is that by going to the gemba you’re able to actually engage in the situation. In fact, you may be able to actually get your hands dirty while helping to solve the problem.

6. Increase the tension

One of the so called contradictions of Toyota is that they often place incredible tension throughout the organization.

This is sometimes done by setting incredibly difficult goals and targets. It’s also done by constantly preaching how the sky is falling and all associates must do their part to help the company stay in business.

So, while there must be a balance, I do think ensuring a fair share of tension exists throughout the organization is a good thing.

7. See the forest

Finally, as a leader one of the most respectful things you can do is to keep your eyes down field.

In other words, don’t lose sight of the forest for the trees. Because if you do bad things will eventually happen… meaning that conversation you’re having – while looking the employee in the eyes – may not be fun.

What do you think?

What other ways, dear readers, can you think of to respect people?