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
September 28, 2011 By 8 Comments
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.
- Starting at the bottom, with the last statement, read it out loud and end the sentence with the word “so…”
- You then read the next statement to make sure it makes sense while ending that statement with the word “so…”
- 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
- Q: Why is the milk spoiled? A: We didn’t drink all the milk cartons before expiration.
- Q: Why didn’t we drink all the milk cartons before expiration? A: We had too many cartons in the fridge.
- Q: Why did we have too many cartons in the fridge? A: We bought more cartons than we needed.
- 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.
- There was a sale on milk and we tried to save money, so…
- We bought more cartons than we needed, so…
- We had too many cartons in the fridge, so…
- We didn’t drink all the milk cartons before expiration, so…
- 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
September 20, 2011 By 3 Comments
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
September 7, 2011 By Leave a Comment
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.
Training Wheels
August 30, 2011 By 9 Comments
My son, who just turned 5 years old, recently taught me a valuable lesson.
Like most young people my boy was itching to take the training wheels off his bicycle.
We had told him that Daddy would take the training wheels off this weekend so he could learn how to ride on two wheels.
Well, apparently, that wasn’t sufficient for him so he decided to take matters into his own hands.
Where’s the wrench?
Specifically, he went into my tool box, found the right size wrench, took the training wheels off his bike by himself, and then commenced to teach himself how to ride on two wheels in our back yard.
We knew he was messing around with some tools and his bike but had no idea he was literally teaching himself to ride on two wheels with no one helping him!
When I finally learned what he was doing I felt bad. I felt like I wasn’t fast enough or that I wasn’t there for him. But then I realized how happy I was that it happened the way it did.
Problem Solving
You see, he knew exactly what he wanted and he decided to make it happen on his own.
The best part of all is he’s learning to solve his own problems. He’s not waiting for people to hand him things on a platter. I fully expect him to become an entrepreneur like his Dad but even if he doesn’t I’m confident he’ll be an amazing problem solver for anyone that employs him.
What about us?
How many times do we grown-ups know what we want to do yet, for some reason, wait for someone to help us or show us the way?
How many times do we continuous improvement practitioners moan and groan about the lack of management support when, in actuality, even though they may not care they won’t stop you from making things better?
So, while it’s a child like analogy (training wheels) the way my son approached one of the biggest challenges of his young life definitely reminded me of how important facing the unknown with relentless determination is.
Do you agree?
Lean Kitchen – Fastcap Style
August 24, 2011 By 2 Comments
Here’s a great example of lean in action within a non-manufacturing situation! Oh, and for the record, my kids figured some of this stuff out months ago! 
Let’s all be friends and focus on making things better
August 17, 2011 By 10 Comments
I’ve sensed an unusually strong disturbance in the Continuous Improvement force the past month or so.
It seemed to start with the announcement that iSixSigma was about to close their doors. Perhaps I’m partially to blame as I wrote an article where I shared my opinions on what I feel is a very sad situation.
In any event, there seems to be more bickering than normal across various Social Media sites such as LinkedIn and Twitter.
You see, many, but not all, hard core Six Sigma practitioners will find ways to snub their noises at the lean crowd while many, but again not all, hard core lean practitioners will find a way to poke at the six sigma folks.
With this said, I often wonder how effective the continuous improvement world could truly be if we focused less on labels (lean, six sigma, TOC, etc.) and more on learning new things and helping others.
Again, I’ll shoulder may share of the blame here… just look at the name of this blog! I fell right into the same labels game when first starting LSS Academy.
In the end, Social Media outlets like blogs, LinkedIn, and Twitter can be very powerful when leveraged for good… but when they become ideological battle fields for people to attack others under the guise of continuous improvement… well, I sometimes wonder if they’re helping at all.
What do you think?
How to Stop Time
August 8, 2011 By 5 Comments
Note from Ron: This is a guest post from James Lawther. Enjoy!
Here’s an interesting link for you. It shows the prices of some domestic appliances in the 1950’s. Sixty years ago you could buy:
- A Sylvania 17 inch black and white TV for $179.95
- An Admiral fridge freezer for $399.95
- A Roll Round vacuum cleaner for $49.00
I had a quick look on Amazon, today I can buy:
- A Phillips 22 inch colour TV for $179.99
- A Sanyo fridge freezer for $329.99
- A Dirt Devil vacuum cleaner for $54.99
Over half a century later I can still buy the same item for the same price, except it isn’t the same item, nothing like the same. Do you fancy staying in and watching a night’s entertainment on a 17 inch Sylvania?
Why do we pay more for services?
Here is another interesting site for you. It calculates inflation statistics. Since 1951 inflation in the US has been 761%. Or to put it another way the $50 you spent in that restaurant last weekend would have cost you $6.57 in 1951.
Now this begs a question. Why is it that we are paying 7 times as much for services now than we were 60 years ago, but we can buy a bigger, better, more reliable TV for the same price? You don’t have to be Einstein to see that something strange is going on.
What is it? Is it that labour costs are lower? Is it raw material costs? Is it energy costs? Is it technology? What is so much cheaper in the manufacturing industry than the service industry? None of those reasons really cut it, to a greater or lesser extent they apply to the service industries as much as they do manufacturing.
Process Improvement
My guess is that it all comes down to process improvement. Over the past six decades manufacturing industries have had wave after wave of productivity improvements, from Deming and Juran, through TQM, 6 Sigma and Lean there has been a remorseless effort to cut costs and improve quality. Once one company started the others just had to follow suit or they would have been out of business, it is what Charles Darwin called survival of the fittest.
The service industries are just starting to get to grips with process improvement. Once they do it will lead to a similar onslaught of productivity improvements. So, if you work for a bank, or a restaurant or a body shop, maybe now is the time to learn a little more. It has been a while since you could buy a Roll Round cleaner.
About the Author
James Lawther gets upset by business operations that don’t work and apoplectic about poor customer service. Visit his web site “The Squawk Point” to find out more about service improvement.
photo credit: 1
3 Things You Can Do When Your Manager Doesn’t Support Continuous Improvement
August 2, 2011 By 9 Comments
We lean bloggers like to preach the importance of senior management support as it relates to continuous improvement.
To be sure, having senior management support is extremely important and without it the hill to continuous improvement success can be mighty steep.
But, let’s be honest here folks. I’m guessing a large percentage of you reading this either have or have had managers who don’t/didn’t support lean and six sigma improvement efforts.
So what can you do if you find yourself in this situation? Here are three things.
1. Make your Manager Shine
Good management is the art of making problems so interesting and their solutions so constructive that everyone wants to get to work and deal with them. ~Paul Hawken
Many times when a manager doesn’t support continuous improvement it’s because they don’t see the value in it.
The best way to combat this is to demonstrate the value without them asking you to.
In other words, make something better and let them know about it.
And when I say make it better I mean it. Do something to positively impact the business.
Do something your manager will be proud to report to their leadership at the end of the month. Work to reduce defects, improve OTD on a key product line, 5S the so called dark corner of the plant.
You see if you make them look good a few times they will almost certainly thirst for more.
2. Self Educate
Get over the idea that only children should spend their time in study. Be a student so long as you still have something to learn, and this will mean all your life. ~Henry L. Doherty
In order for the first point to happen you must seek knowledge. And if your manager doesn’t support continuous improvement chances are they are not willing to fund your lean or six sigma education.
Don’t you dare let this stop you.
There are tons of free lean and six sigma resources available. Click over on our Video tab and watch free Gemba Academy videos. Read blogs like this one and Gemba Panta Rei. Go to the library and read books.
In short, if you truly want to find information you can… and in many cases this information is 100% free.
3. Don’t Give Up
“But the one who perseveres to the end will be saved.” ~Matthew 24:13
In order to succeed at the two recommendations above the most important tip I can offer is to never ever give up.
Sure it’s easy for “experts” to tell you to quit and find another employer who will care… but that isn’t always as easy as it sounds. You have bills to pay and kids to feed now.
So keep fighting… keep learning… keep improving. If you do this, one thing is for certain, you and the organization you work for will be better off even if they don’t realize it.
Farewell iSixSigma
July 25, 2011 By 14 Comments
As some may have already heard iSixSigma is most likely closing its doors due to its parent company Schofield Media losing its bank financing.
A few bloggers and companies selling Six Sigma related products have recently posted their thoughts… some even seem a bit giddy and extremely opinionated about the situation which, quite honestly, saddens me.
I know the iSixSigma leadership team quite well and have communicated directly with them.
I have been told that Andrew Schofield (CEO and Founder of Schofield Media) is still negotiating with Wells Fargo in hopes of salvaging the situation… but, to be sure, things seem grim right now.
Several of the aforementioned bloggers have made it seem as though iSixSigma faltered as a result of poor performance. This doesn’t seem to be the case at all.
Is iSixSigma as popular as it was 5 years ago? Perhaps not since there are many more lean and six sigma sites competing for the same readers. But one thing I know for sure is iSixSigma still receives more unique visitors in one day than most lean and six sigma blogs/websites receive in one month!
Additionally, from what I have been told iSixSigma was well in the black from a financial perspective and the team was extremely excited about their future which included mobile and tablet friendly website technology.
Finally, I have been told that the entire iSixSigma website content has been backed up enabling them to be back online quickly if things do work out.
I literally “grew up” with the iSixSigma website over the course of my continuous improvement career and sincerely hope things work out for them.
I’m curious to hear how many LSS Academy readers have benefited from iSixSigma over the years. Feel free to share your thoughts below.
