The Hello Bar is a simple notification bar that engages users and communicates a call to action.

Complexity and Love Songs

My family and I recently took a much needed vacation. One of our stops was in Chicago where my wife and daughters attended my sister-in-law’s wedding shower.

One of the party favors for the ladies that attended the wedding shower was a CD of love songs friends and family of the bride-to-be chose. Now if you are a guy you’re likely rolling your eyes at this… but I must admit it turned out pretty nice!

Anyhow, the day before the shower I was tasked with the job of putting the labels onto the CDs.

I was given the supplies, trained for a minute or two on how to use the little “fixture” and sent on my way.

The Process (Before Kaizen)

Here are the steps I followed when I first started this little project.

1. Peel off label from the sheet of labels.

2. Place label on the fixture. Note: this was sort of tricky as my fingers kept sticking to the back of the label. See image 1

3. Open CD case and remove disc.

4. Place disc on the top part of the fixture.

5. Press fixture/disc down which joined the disc with the label.

6. Pick up disc and place back in case.

7. Close case.

The Process (After Kaizen)

After trying this a few times I figured there had to be a better way to do this. So I thought about it and ended up with this process.

1. Open CD case and place in front of me while leaving the CD in the case.

2. Peel off label from the sheet of labels.

3. Carefully align and attach label to the disc by hand. See image 2.

4. Close case.

The Results

To be fair, it did take me a few times to practice my “fixture free” approach but after a few attempts I had it down and could perfectly place the labels onto the disc with no problems at all.

But the biggest benefit was the increased speed at which I was able to work. While I didn’t do a formal time study I’m confident I doubled the rate at which I was producing a finished product.

Plus, if I might be so bold… I’d say my quality was even better than the fixture method since there was a small amount of “play” when placing each label onto the fixture which then caused some variability in the finished product.

Complicating things

The thing this mini-kaizen reminded me of is how we producers of goods tend to overcomplicate things with fancy fixtures, robots, and gadgets when all that’s needed is simplification.

It also reminded me how small “tweaks” can lead to huge improvements.

What do you think? Do you agree?

Lean Thinker Interview with Former Toyota Quality Manager

We’ve recently added a new series of videos over at Gemba Academy called the “Lean Thinker Interviews.” During these interviews we’ll be talking to senior lean practitioners about their experiences and life lessons.

For our first edition we’ve interviewed Chris Schrandt, a former Georgetown, Kentucky Toyota Quality Manager. Here is a preview of the 30 minute interview.

The Versatile Leader – Part 3

So far in this series we’ve discussed the directing and coaching leadership styles.

In this article we’re going to move onto the last two leadership styles – encouraging and empowerment.

The Encouraging Leadership Style

The encouraging leadership style is similar to coaching but has a few unique characteristics.

While coaching it’s not uncommon to offer direct feedback and advice as to the performance of the individual or team.

Conversely, the encouraging leader does not offer such direct feedback and advice. Instead, they are there to offer their support and assistance when called upon… but rather than coach and guide they are more apt to encourage and motivate.

The encouraging leadership style might be best suited when an employee has the obvious ability to do the task and has proven many times to be extremely reliable.

However, and this is really the key point, this employee really excels when hearing they are doing a great job and are appreciated.

The Empowerment Leadership Style

Finally, the last leadership style I’d like to share with you is empowerment.

The empowering leader essentially shares the task and/or mission and then lets his or her people go. There is little directing, coaching, or encouraging.

Instead, the leader has complete trust and faith in the person or group they are empowering and simply turns them loose.

In Review

Throughout this series of articles we’ve learned about:

  • The directing leader who offers strong advice and guidance on what to do.
  • The coaching leader who openly listens to and shows interest in the ideas of others in an energetic and passionate manner while also providing regular feedback and constantly monitoring the performance of the person and/or team.
  • The encouraging leader who motivates and inspires without a lot of direction
  • The empowering leader who turns things over to his or her trusted team

The Versatile Leader

As the title of this series states… I firmly believe the best leaders are those that can apply the appropriate leadership style at the appropriate time.

In other words, great leaders don’t always empower when empowering would be disastrous.  For example, my 7 year old daughter needs to improve her softball skills so ‘empowering’ her to excel at this stage would be fools work.

However, I work with some people who are true experts in their trade and don’t need a lot of coaching but do like to be encouraged from time to time.

And, of course, I also know people who most definitely thrive under the empowerment leadership style of management and anything less is actually counter-productive.

Do You Agree and Final Homework

What do you think? Do you agree with me that a leader should be versatile depending on the situation and person they’re dealing with?

Finally, your last homework assignment requires some reflection.  I’d like you to think back to your “favorite boss or leader.”

Once you have this person’s face in your mind I’d like you to think of how they lead you.  Were they dogmatic or versatile?  I bet I know the answer.

The Versatile Leader – Part 2

“That’s what I do now: I lead and I teach. If we win basketball games from doing that, then that’s great, but I lead and teach. Those are the two things I concentrate on.” -Mike Krzyzewski, Duke University

In part 1 of this series we learned about the directing style of leadership. Feel free to check that article out before reading this one.

The Coaching Leadership Style

In this article we’re going to introduce another leadership style – coaching.

The coaching leadership style is best described as one where the leader openly listens to and shows interest in the ideas of others in an energetic and passionate manner.

Additionally, the coaching leader also provides regular feedback and constantly monitors the performance of the person and/or team.

Coach K

I am huge Mike Krzyzewski fan. For those that don’t know… Krzyzewski is head coach of the Duke University basketball team.

The thing I’ve always admired about him is how he is constantly encouraging his players while also teaching and demanding nothing but the best of them.

That, in a nutshell is what this leadership style is all about.

A Word of Caution

For some, coaching comes naturally which can, believe it or not, get you into a jam if you’re not careful.

You see those who get “too engaged” in the coaching leadership style often get far too involved and might end up doing the job, or worse yet, the “thinking” for the person or people they are coaching.

So, keep this mind, the next time you set off to coach someone. Your job is teach, involve, and mentor… your job is not to do it for them.

Your Homework Today

You homework today is simple. I’d like you to read as many of these Coach K quotes as possible. I find them truly inspiring.

Coach K or Bob Knight?

Here’s a question for those of you into American college basketball.  Which coach would you want your son to play for – Mike Krzyzewski or Bob Knight?  Why?

The Versatile Leader – Part 1

There’s one thing I know for sure… being a leader of people is hard work.

No matter if the “people” are those you work with or your children at home… knowing how to best inspire and move them to greatness is no easy task.

However, one thing is certain… great leaders all have one thing in common – they’re versatile. In other words, they are able to adapt their leadership style to the person or situation in front of them.

Along these lines, there are at least 4 different – possibly more – leadership styles that can be used.

And if you’re curious what these are you are in luck as I’ll explain exactly what each of these styles are all about over the next several articles.  So, if you want to be alerted of when these new articles are available please click here and subscribe to LSS Academy.

The Directing Leadership Style

OK, let’s get started.  First we have the directing leadership style which basically means you make the call and people do what you say.

You are not asking for consensus or opinions or alternative ideas. Nope. You are in charge and people better follow.

Sounds sort of harsh, doesn’t it? I tend to agree.

However, if you’re ever faced with extreme adversity (think 9/11) do you want your leaders to ask you to brainstorm for awhile? Possibly “ideate” for a bit? Of course not.

In situations like this we want, and need, leaders to stand up and take charge of the situation.

Additionally, if you are dealing with a new employee or possibly a child, a certain amount of direction is going to be needed from time to time.

Your Homework Today

Throughout this series of articles I’ll be assigning some homework… giving you chance, if you’d like, to practice or at least think about some of the things we’ve covered.

So, today you’re homework is twofold:

  1. Seek out someone who is leading with a directing style. Once you locate the person and situation just observe. How is the “other person” reacting to this directive style? Do you feel this style of leadership is/was appropriate for the situation? Why? Why not?
  2. Reflect on your own leadership style. Ask yourself how often you lead others, even those you may not have direct “authority” over, with a directing style? Has it been appropriate?

What do you think?

What do you think? Do you agree that a directive style of leadership is appropriate in certain situations? Also, do you agree with me that a leader should be versatile? Or do you feel a leader is what he/she is and they shouldn’t attempt to change?

Free 7 Deadly Wastes Overview Video (Spanish Subtitles)

We’ve been unbelievably busy over at Gemba Academy the last few months.

We continue to develop new content (we’re now up to 44 videos, 28 interactive quizzes, 28 PDF summary documents, and much more) and most recently our team has been adding Spanish subtitles to all our videos (other languages to come soon).

Since Spanish is spoken in so many countries we’re doing our best to find a “balance” between the different styles. We know we’re far from done and will most definitely practice kaizen as we listen and learn from customer feedback.

In any event, below is an example of what we’ve come up with to start. If you speak Spanish please let me know how you’d improve things by leaving a comment below or emailing me directly.

Oh, and we’ve experimented with so many different subtitle colors… and believe it or not… yellow has been the run away winner!

To see other free videos please register for a free account on the main Gemba Academy site.

Finally, if you’re reading this via a RSS feed or via email you’ll likely need to click through to the actual article in order to see the video.

If Lean Is So Great, Why Is Toyota Struggling?

Balaji, a reader of LSS Academy, recently sent me the following question/comment via email:

Toyota, GM, and Ford are experts in state of the art assembly technology and in implementing Lean and Six Sigma process improvement methods and so on. Then why have GM & Ford failed? Even Toyota closed its branch production units in Japan? Though I’m also one Lean Six Sigma Black Belt I too lost the confidence that Six Sigma or Lean or TPS can’t do anything in this recession period.

Regards,
Balaji.

Correcting Misconceptions

Before getting started, let me first say that I’ve done some research and don’t believe Toyota has closed any production units in Japan. If I am wrong here feel free to comment below with a correction.

Also, before the lean purists get too excited Toyota does not practice “six sigma” the same way companies like GE and Allied Signal do.

With all of this said, Toyota is still struggling these days just like many other companies.

The company is still deep in the red, logging a net loss of 77.82 billion yen (US$817 million) for the April-June quarter.

How can this be?

So the million dollar question is how did this happen? How could the mighty Toyota, the company that “changed the world” with their production and management system, lose money like this?

The Reality of Running a Business

Well, here’s my take on it.

No matter how amazing your production or management systems are or how well you respect people or how conscious you are of the environment… if no one is buying your product or service problems are coming.

You don’t need to be a CPA to figure this out… if your expenses are greater than your sales you’re in for some trouble.

And it goes without saying that people haven’t been buying many automobiles the past few quarters and no one, including Toyota, saw it coming. Perhaps they should have… but they didn’t.

Now, to be fair, Toyota has weathered this storm about as well as any automotive company SINCE they have an amazing production and management system… but they are not infallible. Far from it.

Rise Up Continuous Improvement Practitioners!

So does this mean lean and six sigma practitioners like Balaji (or you and me) should pack up ship and run for the hills until the orders start flooding in again?

Of course not.

Your company needs you now more than ever. Specifically, they need you to:

  • Attack the waste that is sucking operating income down the drain.
  • Find better ways to manage the inventory that is tying up much needed cash.
  • Reduce lead-times that will make you more competitive.
  • Partner with your sales and marketing team to see how you can apply lean and six sigma principles.
  • Stay positive while working to make things better EACH AND EVERY day even though you might feel like your boss is more focused on other things (like how to make payroll this week).

A “W” Recovery?

This market will eventually turn around. However, I’ve heard some economists claim that we might follow a “W” recovery pattern instead of the more common “V” recovery pattern we often see after recessions.

In other words, things could look better (like they seem to be now?) only to tank once more before the final recovery takes place.

But no matter how things recover one thing is for sure… the companies that work to become stronger during this recession by investing in continuous improvement will be the new winners of the post recession period. This I’m sure of.

What do you think?

Do you agree with me? Do you have any other thoughts on why lean exemplars like Toyota are losing money? Do you agree that investing in continuous improvement is more important than ever in these tough economic times?

Do You Read Much Russian?

The LSS Academy Guide to Lean has been translated to Hungarian and most recently to Russian.

If you’d like to download the Russian version please visit this site (free registration required).

If you’d like to download the Hungarian version please visit this site (no registration required).

And if you’d like to support what we’re doing here at LSS Academy by purchasing the 90 minute audio book version of the LSS Academy Guide to Lean please visit this site.

The profits we make from the sale of this audio book help pay the bills (monthly hosting, website maintenance and upgrades, etc.) so, obviously, your support is much appreciated!

Oh Snap! We Sent Bad Product to Our Customer: Fun with the Hypergeometric Distribution

If you enjoy statistics this is the perfect article for you! But even if hearing the words hypergeometric distribution makes you want to yack all over the floor at least give this article a quick skim as it could prove useful for you someday… especially if you ship a product or service to a customer!

The Scene

To help me with this article I’m going to make up a completely fabricated story.

Let’s say a producer of widgets (replace widgets with the product your company produces if you wish) recently shipped 1,000 units to their customer.

Let’s also say that, prior to shipping these units, the producer randomly inspected 100 widgets.

After inspection, the producer ships the 1,000 widgets to their customer, collects payment, and moves on to the next order.

The Angry Customer

A few weeks later the producer gets a phone call from their customer – who is less than pleased to say the least – explaining that they’ve discovered 4 defective widgets and they hadn’t even looked at all the widgets!

The customer goes on to say that they are sending all 1,000 widgets back and they are giving the producer 10 days to make things right.

Calling All Inspectors

Once the widgets arrive back in the plant a team quickly inspects all 1,000 widgets. Once they are complete they realize that 36 of the widgets were actually defective!

Identified Root Cause

Luckily, the root cause of the defective units was quickly identified and an immediate countermeasure was put into place ensuring this problem would never happen again.

How Did This Order Ever Ship?

The next question that was asked was how this order ever shipped. It was hypothesized that since 100 widgets were 100% inspected at least 1 of the 100 widgets should have been found to defective which would have forced a more thorough inspection of the entire lot.

Bring in the Black Belt

Not sure how to solve this problem the team asked their local Six Sigma Black Belt to help them determine the probability of catching at least 1 defective product while inspecting 100 units out of a lot of 1,000.

The Hypergeometric Distribution

After learning more about the situation the black belt decides to use the Hypergeometric Distribution, which Wikipedia so eloquently defines as a discrete probability distribution that describes the number of successes in a sequence of n draws from a finite population without replacement.

Here is how the black belt set things up in Minitab, which is the statistical software package they use.

In this example we are dealing with a finite population of 1,000 widgets so the “Population size” is 1,000.

Since we know, in this example, 36 widgets were defective and being defective is the “Event” in this case, the “Event count in the population” is 36.

Since the company sampled 100 widgets before shipping the lot, the “Sample size” is 100.

And since, for the Hypergeometric Distribution, X is the number of defective widgets we found in the sample of 100 widgets… X can range from 0 (we found no defective widgets) up to 36 (we found all defective widgets).

Now then, since the Black Belt wants to know the probability of finding at least 1 defective widget, they want to find the probability that X is greater than 0.

So, by using an “Input constant” of 0, they learn that the probability of having no defective widgets in this lot of 1,000 widgets is ~ 2% as shown above.

In other words, there is a 98% chance that at least 1 of the 36 defective widgets should have been detected during the inspection process.

The Conclusion

With this information, the team came to the conclusion that their inspection process was broken. There were three theories that needed to be investigated.

  1. The measurement system is not repeatable and/or reproducible
  2. The units were not inspected at all
  3. Defective units were allowed to pass

So, as is the case with many things related to continuous improvement, answering one question has created several more that need to be addressed.

What do you think?

What do you think of this analysis? Would you have done it another way? What about the conclusions of the team… can you think of another theory of why these widgets were sent to the customer?