Lean Six Sigma Academy

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?

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I just read an excellent post by Jamie Flinchbaugh titled A Call to Action.  The basic premise of Jamie’s thoughts are to stop talking about things… instead take action.

So, your homework for this week is two-fold.

1. Read Jamie’s post.  It will take less than 45 seconds as it’s a short one.
2. Take action on a project or task you have been putting off this week.

That’s it.  Two things.  I know you can do it!

As those that follow Major League Baseball know, umpire Jim Joyce cost pitcher Armando Galarraga a perfect game earlier this week.

For those that don’t know the story, Detroit Tiger pitcher Armando Galarraga needed one more out in order to cement a perfect game.

And on what looked to be a routine play… it seemed he had it as he stepped on first base ball in hand a full step before the runner did.

Unfortunately, umpire Jim Joyce didn’t see it the same way as he called the runner safe.

To be blunt, it may go down as the single most “blown” call of all time. After watching a replay Joyce commented, “Oh my God, it was out. Not even a close play.”

And while the baseball fanatics are screaming for more instant replay I, myself, have been overwhelmed with another aspect of the story.

You see, for me, the “story” is all about the way Jim Joyce handled his mistake.

He didn’t make excuses. He didn’t blame anyone else. No, he admitted his mistake with sincere contrition.

The image above is of him stepping onto the field the night after his mistake. He was crying and he hugged Galarraga and apologized.

It’s life lessons like these I want my children to learn. You see, everyone makes mistakes. Everyone.

But not everyone takes complete ownership for their mistake the way Jim Joyce did.

I do feel bad for Armando Galarraga. To be sure, he was robbed of a magical moment. A moment he may never get close to again.

But, perhaps the life lesson Jim Joyce taught millions of people around this country – and perhaps the world – will make more of an impact when it’s all said and done.

Well done, Jim Joyce. Well done.

I recently facilitated a SMED kaizen event.

Over the years I’ve been fortunate enough to facilitate events all over the world. But this event was different. Very different.

You see this kaizen event was in France and short of two team members, no one spoke English!

And to complicate matters even more my French is not exactly good… beyond oui, bonjour, and merci I’m pretty much done.

But through a translator and a lot of unspoken direction we managed to radically reduce a machine changeover time.

I was pleased with the results, no question. But the thing I was most happy with was the transformation of the shop floor workers throughout the week.

You see, it makes no difference where in the world kaizen is done… chances are there will be some folded arms and resistance on day 1. This is normal and I expect it. Heck, I welcome it!

But, done correctly, kaizen always opens the minds of associates who are being asked to engage in improvement like never before.

You see if we take the time to involve, challenge, and really listen to people at all levels good things will happen.

Will you always reduce changeover time by 50%? No. But that’s not the most important aspect of kaizen if you ask me.

The most important aspect of kaizen – to me – is seeing the smiles, and even tears from time to time, of kaizen team members as they proudly report to their General Manager on the improvements realized.

Done correctly kaizen opens minds. Done correctly kaizen penetrates the soul. Done correctly kaizen changes lives for the better.

This is why I love kaizen.  Do you love it too? Why?

I recently wrote about the Long and Winding Road of P90X and Continuous Improvement.

In this article I want to share some ideas for how to approach things such as workout programs and continuous improvement as they are surprisingly similar.

Let’s get started.

Tip 1: Have a Good Coach

In my opinion, the P90X program works because of the charismatic, and extremely passionate, Tony Horton.

This guy, in his mid 40s at the time the videos were shot, has more passion and energy than any person I’ve met. Ever.

Tony makes working out fun… mostly. I mean there are points where I feel like punching him in the face because I want to vomit and I hurt all over. But, for the most part, I love the guy!

And to succeed at continuous improvement I feel it’s also very important to have a good coach to push you and move you out of your comfort zone.

The coach doesn’t have to a consultant either. They could be a colleague or your boss or someone else in your life that has traveled the journey before.

In the end, all that matters is that you have access to someone that can mentor, challenge, and encourage you as you progress on this long and winding road called continuous improvement.

Tip 2: Have a Plan

Next, P90X has been carefully designed. The program follows a system of muscle confusion meaning your body never gets used to the workout. And, as such, your muscles develop much faster.

In the same way, if you don’t have a plan – or a vision – for what you want your organization to look like in 1 year, 3 years, and 10 years… get one.

In fact, I’d strongly advise you to not even begin your journey until you take the time it takes to develop a plan.

And, again, if you don’t know what “good looks like” I’d strongly encourage you to seek the help from those that do.

You likely have people working in your organization that have seen “good” and have never been asked. So ask them.

Or, if you don’t have anyone to lean on, no pun intended, you would do well to bring in good consultants to help you begin the journey… or better yet you might do well to hire a full time employee with loads of experience to help you shape the future of your continuous improvement journey before you.

Tip 3: Persevere

Finally, the last piece of advice I can offer is the easiest to say but hardest to do – persevere.

As it relates to working out… it’s so much harder to get into shape than it is to fall back out of shape. And the only way to get into shape is to work out, eat right, and get adequate rest so your body can repair itself. Easy to write… much harder to practice.

Likewise, continuous improvement – be it lean, six sigma, TOC, etc. – is not easy.

You’ll face severe resistance from C.A.V.E. people. And some, including senior leaders from time to time, will say they support the journey… until it “gets in their way.” Fight through this and don’t give up.

You’ll also make mistakes. A lot of them. In fact, if you’re not making mistakes… you’re probably not trying hard enough. The key is to learn from these mistakes and quickly get back on the saddle to ride again.

In summary, even though the journey is hard, long, and sometimes lonely… don’t ever quit. Don’t let bad attitudes and setbacks keep you from moving yourself and your organization forward.

You see, done right continuous improvement will change lives for the better. This, I guarantee.

What do you think?

So, these are three areas of focus I feel to be extremely important. Do you agree with them? Would you add anything? If so, what?

As I come up on the 90th day of my P90X workout program I can’t help but compare the situation to the continuous improvement journey.

You see, by definition, the P90X program is meant to get you into top shape within 90 days. And, let me tell you, it’s worked wonders with me. I feel great and look better than I have since my college days.

But here’s the thing… I can’t help but wonder how many people finish P90X and then, sadly, fall back to their “old” way of life of not working out, eating bad, etc.

The Continuous Improvement Journey

One could say the same dilemma occurs for those starting their journey with continuous improvement.

Initially we’re consumed with excitement, passion, and vigor. Things are changing, people are motivated and real, authentic transformation is happening all around us.

But, alas, as with most things the excitement wanes.

That 4 day training class seems like it was years ago. The lean workbooks once referenced by the team have now taken their final resting place on the bookshelf. And sustaining the improvements seems like more work than it’s worth.

The Wrong Approach

But it doesn’t have to be like this. While the P90X is meant to get you into top shape in 90 days it doesn’t have to end there.

The program provides you with ideas for how to continue the journey… how to mix things up, increase the intensity of the program, etc.

This is exactly how I intend to continue my P90X journey. You see I don’t plan on stopping because if I do… well, I know I will backslide in a big way.

The Long and Winding Road

So, while the marketing genius of P90X  is unquestioned (they’ve sold millions of DVDs) I do wish they’d put more focus on how to continue after 90 days.

Likewise, those that think a workbook or 5 day training class will get them where they need to be with respect to continuous improvement are sadly mistaken.

It’s a journey folks… and a long one at that.

There is No Easy Way

There are no easy ways to getting into shape. It takes hours and hours of work. It takes sweat. It takes pain. It takes dedication.

Likewise, there are no easy ways to authentic continuous improvement. It too takes sweat. It too requires pain. It too takes dedication.

In our next article I’ll share some tips on how to approach this journey in such a way as to maximize your chance of success.

Questions for P90X Alums

Until then, if you’re a P90X ‘alum’ I am curious to learn how you approached things after 90 days. Did you stop? Continue? Or start something else up?

One of my favorite quotes from the P90X training videos goes like this.

“If you can eliminate the mindset that ‘I can’t. I can’t do pull ups.’ Forget I can’t – say ‘I presently struggle with’ and if you keep that mindset then over the course of time, someone who’s dream was to do two or three could turn it into twenty and more. - Tony Horton, P90X”

The reason I love this saying is you can replace the words “do pull ups” with just about any other phrase imaginable.  And, sadly, many people do.

And no matter if it’s my children saying I can’t or a grown-up resisting the idea of 5S in their work area the problem is the same.

Pure Poison

You see, I believe the words I can’t are pure poison. In fact, these 2 words are like a deadly disease gone viral.

The minute someone says they can’t do something others, even those with positive attitudes, are almost certainly demotivated. Worse yet, others may actually believe they can’t do something as well.

I Presently Struggle With

And while there are some things we indeed can’t do (think birthing children men) in most cases there is no reason to ever utter – or think – these poisonous words.

So, the next time you find yourself saying (or thinking) I can’t just stop.  Then breathe.  Then replace the words I can’t with I presently struggle with.

You, and everyone around you, will be better for it.

Do you agree?

Which do you feel is more important – hard work and hustle or brains and intelligence?

In other words, if you had to choose between the following two people to run your family business… who would it be?

• Person 1: Average intelligence but an unbelievable drive to succeed.  This person has had to work hard for everything they have ever gotten.

• Person 2: Off the scale intelligence but an average drive to succeed.  This person has always been the smartest around and, as such, has never really had to work hard at anything in their life since most things come naturally.

What do you think?  Who will you choose to run your company?

Another hat tip to Jon Miller for first posting this video of Paul Akers and the FastCap team practicing lean thinking.

What you think of this process? Do you do something similar at your place of work?