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The Courage to Try

I was recently speaking with a Gemba Academy customer who’s looking to start a small lean consulting company. I’ll call this person Bob for the sake of this article.

About Bob

Bob explained that he doesn’t have a college degree but does have many years of practical, real world, experience.

Bob has also sought, and received, a lot of continuous improvement training (lean and six sigma) on his own. As such, Bob seems to really know his stuff.

The Most Important Characteristic

As we continued our discussion Bob asked if I had any advice on how to best deal with clients once the consulting engagement begins.

The main thing I explained was how important it is to be confident in your skills and advice.

I also explained what I believe is the most important characteristic any lean or six sigma practitioner can have. And this characteristic is to always have the courage to try.

Having the Answers

You see, contrary to popular belief, the best lean and six sigma practitioners don’t have all the answers… but they do have the courage to seek solutions through problem solving and root cause analysis.

Furthermore, the best lean teachers are those who understand the simple statement, “What do you think?” may just be the most powerful reply to any question they receive.

Finally, the best teachers I’ve ever had are those who aren’t afraid to try and fail since, as Sir Winston Churchill once explained, “Success is not final, failure is not fatal: it is the courage to continue that counts.”

What do you think?

What other bits of advice do you have for Bob? I’ll be sure to send him a link to this article and I know he’ll appreciate learning from your wisdom and advice.

So what do you think?

Live Built in Quality Seminar in Denton, TX

Peterbilt Motors, Gemba Academy and Kaizen Institute are pleased to present a half-day live workshop on Monday December 5th 2011 on the subject of “Built-in Quality”, one of the two pillars of the Toyota Production System house.

What is Built in Quality?

Sometimes called jidoka or autonomation, the lean approach to quality is to develop processes that prevent, detect, contain and countermeasure errors. The aim of a Built-in Quality system is to stop defects from being passed to the next process i.e. the customer.

Commonly expressed “Don’t accept, make or pass on poor quality” this is possible only by understanding how various principles and tools interact within a Built-in Quality system. These enablers include the andon system, the stop-and-call / stop-and-fix principle, Quality Key Points within standardized work, rapid response teams, practical problem solving, mistake proofing, process capability and many others.

About the Presenter

The seminar speaker will be Chris Schrandt, Senior Consultant with Kaizen Institute. Chris has taught kaizen and the Toyota Production System (TPS) for the past 23 years in the USA, Brazil, Argentina, Sweden and Mexico in manufacturing, healthcare and service fields. Chris gained a deep understanding of Built in Quality over 10 years as Quality Engineering Manager with Toyota in Georgetown, Kentucky.

Chris learned under Japanese coordinators and experts, and directed a team of 40 engineers and support staff responsible for improvement projects across multiple suppliers and processes.

Where and When

Monday, December 5, 2011
8:00AM – 1:30 PM (lunch provided)
Peterbilt Motors Company
3200 Airport Road
Denton, Texas USA

Cost

The cost is $150 per person, including lunch and printed materials.

Learn more here.

Gemba Glossary: Value Stream

Here is the next video in our Gemba Glossary video series. This one focuses on the Value Stream. If you missed any of our earlier Gemba Glossary videos please follow the links below.

Also, we’re running our Free 30 Lean DVDs promotion this month.  To learn more about this limited time offer please click here.

Finally, if you are reading this via email or RSS you may need to click through to the site to see the video.

 

iSixSigma is Back!

Just got this message via email.  This is GREAT news for the continuous improvement world. 

iSixSigma Founder Promises Rebirth of Lean Six Sigma Website
Readers will again have access to the best Six Sigma, Lean and operational excellence resources as well as more ways to share, learn and discover

BAINBRIDGE ISLAND, Wash. (Nov. 7, 2011) – iSixSigma.com, the leading online community and resource portal dedicated to Six Sigma, Lean and other operational excellence methodologies, is back under the ownership of the website’s creator, Michael Cyger. Plans are under way to “rebuild the functionality of iSixSigma.com from the ground up,” Cyger said, “taking advantage of the tens of thousands of articles, tools and resources already created.”

iSixSigma, as well as several other Internet properties, were sold to Schofield Media Group by Cyger in 2008. Now that he has reacquired the assets of the website, iSixSigma.com will become part of Web X.0 Media, an Internet publishing company Cyger launched in 2009.

After eight years operating the largest Lean Six Sigma portal and as a Six Sigma veteran of GE and Citigroup, Cyger is rooted in process improvement. “I’m excited to be back involved in the Six Sigma and operational excellence industry,” Cyger said. “I see this as a tremendous opportunity.”

The iSixSigma founder plans to work closely with the community during the next month to develop innovative features to help the community share, learn and achieve higher levels of operational excellence faster. “When iSixSigma.com went offline in August, I received many calls from people in the industry who wanted to see iSixSigma.com get back on track. I appreciated the outpouring of support and look forward to serving this exceptional community,” Cyger said.

About iSixSigma: Since 2000, http://www.iSixSigma.com has provided the most comprehensive and essential resources available to businesses at every stage of their Lean Six Sigma maturity and to professionals at every skill level. Hundreds of thousands of monthly online readers learn new skills, advance their careers and contribute to the success of their organizations through a wide range of articles, blog posts, tools and a discussion forum. In addition to publishing, iSixSigma operates a jobs board at http://jobs.iSixSigma.comand a marketplace at http://store.iSixSigma.com.

Web X.0 Media uses next-generation Internet technologies to publish content on relevant, informative topics. Web X.0 Media is located in Bainbridge Island, WA.

 

The 7 Steps to Hoshin Kanri

Gemba Academy recently added their 211th video to their constantly growing online and DVD based Lean Training System.

To celebrate breaking the 200 video milestone they’ve brought back their extremely popular Free DVDs promotion. All the details can be found here.

This newest course is focused on Hoshin Planning, commonly referred to as Hoshin Kanri or Policy Deployment.  During this course students also learn how to use the simple, but very powerful A3 document.

The first video, of this 11 video course, shown below introduces the Hoshin topic while also explaining the 7 steps to Hoshin Planning covered in detail later in the course. 

Here is a PDF Summary Document for this first module that you can print out and read at your convenience. 

If you’re reading this via RSS or email you may need to click through to the site in order to see the video.

How to Not Demotivate People

Here is a short, but excellent, video on how to not demotivate workers. The person speaking is Jim Collins, author of the bestseller Good to Great.

I’d be curious to hear your thoughts on whether you agree with everything Mr. Collins says in this video. If so, why? If not, why?

Applying TPS Beyond the Shopfloor

Here’s a short, but very powerful, video of how lean thinking principles can make a massive impact on society.  Well done Toyota!

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

The Last Step to 5 Whys Process – The “So What?” Test

The 5 Whys Process is an extremely powerful root cause analysis technique when applied properly.

As we explained in our recent Gemba Glossary video focused on the 5 Why there are situations where asking why a few times will suffice while other situations may require more in depth questioning that could lead to several “branches” of why questions.

With this said, one technique I strongly encourage all lean and six sigma practitioners to practice is what we call the “So what?” test.

Steps to the So What Process

Once you and your team, since the 5 Why Process is best done with a team, believe you have identified a root cause worthy of further investigation the “so what” test can done as follows.

  1. Starting at the bottom, with the last statement, read it out loud and end the sentence with the word “so…”
  2. You then read the next statement to make sure it makes sense while ending that statement with the word “so…”
  3. Repeat these steps until you reach the top statement in the analysis

Spoiled Milk Example

Let’s go ahead and use the same spoiled milk example we introduced in the Gemba Glossary: The 5 Whys video.

In that example our 5 Whys analysis (4 whys were asked in this example) resulted in the following.

Problem: The Milk is Spoiled

  1. Q: Why is the milk spoiled? A: We didn’t drink all the milk cartons before expiration.
  2. Q: Why didn’t we drink all the milk cartons before expiration? A: We had too many cartons in the fridge.
  3. Q: Why did we have too many cartons in the fridge? A: We bought more cartons than we needed.
  4. Q: Why did we buy more cartons than we needed? A: There was a sale on milk and we tried to save money.

Ask So What?

To practice the “so what?” test all we need to do is work backwards stating “so” at the end of each statement. Let’s see what this looks like.

  1. There was a sale on milk and we tried to save money, so…
  2. We bought more cartons than we needed, so…
  3. We had too many cartons in the fridge, so…
  4. We didn’t drink all the milk cartons before expiration, so…
  5. The milk is spoiled.

Just Common Sense?

Now, as simple as this is, some may think it’s a waste of time to ask so what… it’s not. You’ll be amazed how many times things don’t make sense when adding “so…” to the end of each statement like this thus identifying a need to re-examine your 5 why analysis.

What do you think?

Have you ever tried this approach? If so, how has it worked out? Do you have another technique for checking the results of your 5 why analysis before attempting to apply a countermeasure? If so, how do you go about this?

Gemba Glossary: The 5 Why

Here is the next video in our Gemba Glossary video series. This one focuses on the 5 Why. If you missed any of our earlier Gemba Glossary videos please follow the links below.

Also, we now offer more than 200 lean training videos in the Complete Lean Package… be sure to sign up for a Free Lean Starter Account to check things out.

Finally, if you are reading this via email or RSS you may need to click through to the site to see the video.

Applying 3P to Healthcare & Beyond

Gemba Academy has just released its latest online lean training course focused on the application of 3P (which stands for Production Preparation Process) within the healthcare world. 

And while the course, which is delivered by Mike Wroblewski, is healthcare focused the 3P principles taught apply to any industry. 

This 3P course is available on DVD as a standalone product and is also bundled within the Complete Lean Package which now contains 199 lean training videos

Free Multi Site DVD Promotion

Next, we’re also running a special Multi-Site Free 28 DVDs promotion this month.  All the details for this free DVDs promotion can be found here.

3P Overview Video

Finally, here is the first “Overview” video of the newest 3P course.  If you’re reading this via email or RSS reader you’ll likely need to click through to the site in order to watch the video.

Viewing Tip: Click 360p in the lower part of the player and select 720p for a sharper picture.