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Webinar Replay: Using SPC to Make Better Management Decisions

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.

Happy Birthday, Webinars, and Kanban

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.

Free TPM & Leader Standard Work Training in the DFW Area

If you live in the DFW area, or will be in the area, you are cordially invited to attend Gemba Academy’s first ever “live” training seminar.

Who and What

Mike Wroblewski, of Gemba Consulting North America, will deliver free, as in no cost, training on the following topics:

  • Leader Standard Work: How leaders can, and should, use the proven principles of Standard Work to guide their daily work.
  • Total Productive Maintenance (TPM): You will learn what TPM is and how it applies to anyone who cannot afford unplanned equipment downtime. 

Where & When

The training will be held at the Peterbilt Manufacturing Facility located in Denton, TX this coming Tuesday, February 15.

We’ll start the training at 8:00 AM and end no later than 1:00 PM. Snacks and lunch will be served.

Why is it Free?

Nothing in life is ever free… so what’s the catch?

Well, the catch is we’ll be video taping these training sessions for inclusion into Gemba Academy’s growing library of online and DVD based lean training.

But, don’t worry… our camera crew will be focused on Mike so you don’t have to be on camera unless you want to of course!

How to Register

Space is definitely limited so if you’re interested in attending this free training please contact us immediately by email or by calling 866-599-1398.

Once we reach capacity we’ll have to turn requests away so if you are interested please contact us as soon as possible.

The Soccer Coach

I recently completed one of the most humbling experiences of my life… I coached my daughter’s U7 soccer team.

The main challenge for me was that I never played soccer growing up. As such, I had a lot of learning to do before I could expect to help the girls.

Looking back on the experience, I see many parallels to the world of continuous improvement.

Education

The first thing I had to do was educate myself as quickly and efficiently as possible. To do this I read several books and watched an intense soccer DVD training program. It took me a few weeks to get through the whole program but the information I learned really helped me.

So, if you are new to continuous improvement you must educate yourself through self study and/or formal training of some kind.

Self Practice

As I was learning things I practiced myself. There were many late nights where I stood in my living room with a soccer ball at my feet practicing different techniques I was learning about on the DVDs.

So, while reading a book or sitting through some sort of training is essential… so too is practicing. If you never try, and fail from time to time, you will never succeed over the long term.

Go to Gemba

Once I had some basic skills in mind it was time to go to gemba, or the place the work is done. Initially, the gemba was my backyard and my pupils were my kids!

Both of my daughter’s play so I was able to teach them some of the new things I learned about. I was also able to learn how to adjust my “coaching” style for young people.

Over the past few months me and my kids have spent hours and hours passing, dribbling, and shooting the ball in the backyard.

So, until you actually go to gemba and try things out you will never truly learn them.

Have a Plan

Once our team began to practice as a group I quickly learned how important it was to have our practices well planned… down to the minute in fact.

I also arrived 30 minutes early to get the practice cones laid out and to make sure we were ready to start on time.

Since I was coaching girls ranging from 5 to 7 it was important to keep things moving and to not allow them time to goof off.

So, being organized and having a plan of exactly what you want to accomplish is very important no matter if you are coaching soccer or facilitating a kaizen event.

Seek & Welcome Help

Finally, a few games into the season one of my parents volunteered to help me coach. This gentleman was an absolute blessing as he played and continues to play soccer as an adult.

Between the two of us we were really able to coach the girls up in a more effective manner.

So, it’s my opinion, that only a fool turns away help from people genuinely interested in making things better.

In other words, no matter where you are on the continuous improvement journey I’d encourage you to seek out others who might be able to help you grow as an individual and organization.

Indoor Here We Come

Our outdoor season ended a few weeks ago and most of the girls signed up to play indoor soccer. And, yes, I am coaching them.  So, the saga continues!  Stay tuned for more updates. 

What do you think?

Have you ever coached a youth sports team? If so, do you see any parallel’s to the world of continuous improvement?

A Different Way to Learn

A big hat tip over to Kevin Meyer or Evolving Excellence for sharing this video with me.  It’s a fascinating story of how some children are learning more than anyone could ever imagine possible.  I’m definitely interested in your thoughts on this one! 

If you’re reading this via email or RSS you’ll need to click through to the site to watch this video.

Gettin’ Jiggy With It

I’ve been doing a tremendous amount of classroom training the last few weeks. As an aside, if you’re interested in having me or one of my colleagues conduct in person training (lean or six sigma) please contact us.

Anyhow, over the last 14 days I’ve taught more than 40 people everything from hypothesis testing to the different types of pull systems used during lean implementations.

The students have been fabulous and a true joy to teach… but that’s not the point of this article.

You see, while teaching these classes I was reminded of how important it is to just chill out and have some fun. Allow me to explain.

Teaching Stats is Boring

Teaching statistics to a bunch of Black Belts is not always exhilarating. There’s some math and, for some, that isn’t much fun.

Well, during one of the harder lessons on Advanced DOE (Response Surface Optimization) I decided to shake things up a bit… and by shake I really do mean shake.

Half way through this lesson we were transitioning into the teeth of the concept and I knew some students would be intimidated.

Getting’ Jiggy With It!

To counter this, I inserted a funny slide with the picture of a crazy dog dancing summarizing how we were going to take things to the next level. In other words we were about to “get jiggy with it!”

I also had Will Smith’s song “Getting’ Jiggy with It” automatically play when the dog picture appear. To add additional shock factor I asked one of my colleagues to come to the front of the room before the slide (and music) played.

Once he and I were in position I transitioned to the slide… as the music started to play we both started to dance like true fools for about 15 seconds.

My colleague attempted a form of the “sprinkler” and only the good Lord knows what my little dance moves should be called. As an aside, I’m the guy on the right in the picture above… and to protect the innocent I’ve blurred out my colleagues face so he doesn’t shoot me. Ha!

Total Engagement

But here’s the thing… once the class got over the shock of what was happening they exploded into applause. And I really mean exploded!

And most importantly… the class was totally engaged and ready to learn. They were having a tremendous amount of fun and things went far better than I ever expected with the teaching of Response Surface Designs.

The True Lesson

The true lesson for me was to never forget how powerful a little shock and extreme laughter can be.

If you are a consultant or trainer of any kind I strongly encourage you to stop taking yourself so seriously. You’re not a professor attempting to make people fall asleep. And chances are good that the material you’re presenting is pretty boring. Sorry, but it’s true.

So, don’t be afraid to shake things up a bit. And don’t be afraid to act like a fool for 15 seconds. It just might engage your students like never before!

Do you agree?

The Art of Instruction

Boy raising his hand

“I never teach my pupils; I only attempt to provide the conditions in which they can learn.” ~Albert Einstein

Last night we discussed two different learning theories – entity and incremental.

I read about these theories in the book The Art of Learning which was written by Josh Waitzkin – an eight time National Chess Champion and subject of the book and movie Searching for Bobby Fisher in his youth.  He then went on to win twenty-one National Championships in martial arts in his later years.

In last nights article I explained that even though an individual is plagued with an entity theory learning style, meaning he or she sees their knowledge level as a “thing” or “entity” that cannot evolve, they can change.

Nothing to do with intelligence

Now then, it should first be noted that, according to Waitzkin and other developmental psychologists, an individual’s intelligence level has nothing to do with their learning theory. Instead, these individuals – especially children – are basically handed their learning theory based on the instruction they receive from their teachers, parents, etc.

Forming an Entity Theorist

There seems to be a very fine line in how instruction can and should be delivered in order to either help or harm the student.  Waitzkin writes:

Entity theorists tend to have been told that they did well when they have succeeded, and they weren’t any good at something when they failed.

So a kid aces his math test, comes home, and hears “Wow, that’s my boy! As smart as they come!” Then next week Johnny fails his English test and hears “What’s wrong with you? Can’t you read?” or “Your Mommy never liked reading either – obviously it’s not your thing.”

So the boy figures he’s good at math and bad at English, and what’s more, he links success and failure to ingrained ability.

Now, you may be thinking… what kind of jerk parent would act like this? I hope the answer is not many. Sadly, I imagine there are a few.

But what about at the office or in the plant? Have you ever known a manager to ridicule an employee who made a mistake, or made someone feel like they were just a replaceable number in the ERP system? I sense a few more hands going up into the air.

Forming an Incremental or Learning Theorist

Waitzkin then goes on to explain the other side of the coin.

Learning theorists, on the other hand, are given feedback that is more process oriented. After doing well on an English essay, a little girl might be congratulated by her teacher with “Wow, great job Julie! You’re really becoming a wonderful writer. Keep up the good work!”

And if she does badly on math test, her teacher might write “Study a little harder for the next one and you’ll do great! And feel free to ask me questions any, that’s what I’m here for.”

So Julie learns to associate effort with success and feels that she can become good at anything with hard work. She also feels as though she is on a journey of learning, and her teacher is a friendly assistant in her growth.

What do you think?

What do you think about all this? I got several emails today about my article last night. Some folks agreed…. while some saw things differently. I’d love to hear your thoughts.

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Two Approaches to Learning

Hermit CrabHave you ever watched the movie Searching for Bobby Fisher? It’s the one about the child prodigy chess player. Well the child, Josh Waitzkin, is all grown up now and has written a book called The Art of Learning.

I am not done with the book yet, and will offer more detailed insight later, but I did want to share one of the topics of discussion with you this evening.

In the first part of the book Waitzkin discusses some “foundational” topics – one of them being how there are at least two approaches to learning.

He gives credit to a certain development psychologist named Dr. Carol Dweck for identifying the distinction between the entity and incremental theories of intelligence.

Entity Theorists

Waitzkin explains:

Children who are entity theorists – that is, kids who have been influenced by their parents or teachers to think in this manner – are prone to use language like “I am smart at this” and attribute their success or failure to an ingrained and unalterable level of ability. They see their overall intelligence or skill level at a certain discipline to be a fixed entity, a thing that cannot evolve.

Now re-skim that paragraph only this time replace the words children and kids with men or women. Do you know any entity theorists? I do.

Incremental Theorists

Waitzkin goes on to explain how incremental theorists are very different.

Incremental theorists, who have picked up a different modality of learning – lets call them learning theorists – are prone to describe their results with sentences like “I got it because I worked very hard at it” or “I should have tried harder.” A child with a learning theory of intelligence tends to sense that with hard work, difficult material can be grasped – step by step, incrementally, the novice can become the master.

Hermit Crabs

Waitzkin uses a hermit crab to describe the differences between the two theories. He explains that as time passes the hermit crab eventually out grows its shell and must find a new one.

Since the hermit crab is a very soft and delicate creature this transitioning period from the old shell to a new shell can be very dangerous due to predators, etc. Waitzkin then writes:

That learning phase in between shells is where our growth can spring from. Someone stuck with an entity theory of intelligence is like an anorexic hermit crab, starving itself so it doesn’t grow to find a new shell.

I absolutely love this analogy!

It’s about Instruction

The good news is any child (or man or woman) can be transitioned from an entity theory learning style to an incremental theory of learning with ease. Tomorrow night I’ll explain!

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Rope Suppliers

J Thatcher recently asked:

Here’s a question:

If the student becomes the initiation point for “pull” learning, how does the instructor continue to “push” students beyond what they believed themselves capable? (And yes, I’m using “push” differently there)

rope.jpgThis is not an easy question to answer and one I have spent several hours thinking about.  This type of question relates to  teaching kids for sure.  But it also relates to us grown ups who work in factories, hospitals, and board rooms. 

We too can initiate pull learning but how do we keep motivated to continue the journey?  How does our “instructor” or boss or board of directors continue to push us?

Understanding Current State

Well if I think about my kids and how my wife and I are trying to “push” them as they pull at their own speed I realize that one thing we are constantly doing is understanding where they are.  While my daughter may be excelling in one area my wife knows about it.  And she is preparing the next lesson accordingly.

So, while my little girl is able to pull at her own speed my wife and I are right there making sure she doesn’t actually run out of rope.  So, you could say we are rope suppliers in a peculiar kind of way. 

Likewise, if we see our child struggling with the rope we engage and help her pull a little.  Then, as she regains her momentum we back off and resume our rope supplier role.

Same thing for us Grown-ups

It’s the same thing in the corporate world if you think about it.  A good leader is one who recognizes the current state of affairs by going to see what is happening on the gemba (genchi genbutsu).  They know where the organization’s strengths and weaknesses are.  And they engage and help pull the rope when required (kaizen).

But more times than not these leaders are looking ahead to ensure their team of motivated and pulling employees never run out of rope to pull (hoshin kanri).  In short, they are rope suppliers too.

Anyhow, that’s my two cents on it.  What do you think? 

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Should we Push or Pull in Schools?

child-pulling-on-a-rope.jpgMy good friend, and excellent blogger, Mark Graban posted an interesting article related to how a school is using continuous improvement methods to, well, improve things.

For those who don’t know, Mark and I live in the same town and have actually become good friends. The thing I really respect about Mark is how he will challenge anyone when he thinks he is right. That is refreshing to me as there are far too many “yes-men/women” in this world.

Anyhow, Mark and I are having a nice friendly conversation over on his blog (see bottom of the post I linked above) about Six Sigma, GE, Karoshi and all kinds of fun stuff. But that is not what I want to write about tonight.

Push or Pull Learning?

Instead, I want to talk about one of the things Mark mentioned in another comment. He wrote:

“Do you error proof how math is taught? Do you have students “pull” learning instead of “pushing” it at them? Probably not….”

That last sentence caught my attention, “Do you have students “pull” learning instead of “pushing” it at them? Probably not…”

I respectfully disagree with Mark here.

I am of the opinion that children learn the best when they are allowed to excel in areas they are good at and move slower in areas they are not so good at.

In the traditional American public school room the pace is set by the slowest kid for the most part.

Little Bobby and Susie

If Bobby, for example, is slow at learning multiplication while little Susie has it mastered after the first lesson, chances are Susie is going to be forced to sit there bored stiff while the grossly underpaid teacher does her best to help Bobby.

Further, if Bobby begins to “sort of” get it but really needs more practice the teacher will likely “push” on since she sees poor Susie, bless her heart, waiting so patiently.

If you look at advanced programs in schools we see children allowed to move at their own speed. No one is slowing them down and nothing is being pushed on them.  Instead these kids normally pull… and pull hard.  There is a similar thing happening in most Montessori schools.

Time to Come Clean

I must confess I am a bit biased here since my wife is home schooling our 5 year daughter this year. My kiddo is supposed to be in kindergarten but since she has blown through the kindergarten curriculum (a Catholic school curriculum) she is now onto first grade (again a Catholic school curriculum).

How is it going?  Well my 5 year old daughter, if you will allow me to brag a bit here, is already reading at a first grade level and, oh yeah, already knows how to multiply. She had double digit adding and subtracting down at 4 years old. And most importantly to me and her mom, she is really learning her faith.

So, had we put her in a traditional school this year she would probably be bored stiff. In fact, she could have easily been the sweet little Susie I mentioned above.

Dora Academy

Of course, the danger here is not all parents will make sure their children are doing their best to pull knowledge. To some, their idea of home schooling may be turning on Noggin at 8:00 AM to let Dora and Boots teach them all they need know.

In these very unfortunate situations I would agree… get that kid in school and push that education down their throats.

In Goldratt we Trust

One last thing, people like Eli Goldratt (TOC guru) are now working to change the way kids are taught. I really hope people listen to him and would like nothing more than to see experts in lean manufacturing and six sigma step up the plate as well. Our kids are depending on it.

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