Lean Six Sigma Academy

Gemba Academy, which for those that don’t know is a company I helped co-found along with Jon Miller of Gemba Panta Rei and Kevin Meyer of Evolving Excellence, is about to release our newest course focused on the 7 Quality Control Tools, or 7 QC Tools for short.

Contrary to what some think, lean thinking companies are very concerned about quality control which is why we’re so excited about this course.

We’ve already released this first overview video to Gemba Academy subscribers… but other than that no one else has seen it except readers of LSS Academy!

Finally, if you haven’t already done so… be sure to register for a free Lean Starter Package account which will grant you immediate access to more than 1 hour of free online training on lean manufacturing concepts such as 5S, the 7 Wastes, Value Stream Mapping, Quick Changeover, and Practical Problem Solving.

Sorry for the sales pitch! I just get a little excited talking about Gemba Academy. Anyhow, check out the video below by clicking on the arrow in the middle of the player. After that be sure to register for a free account and check out the other free videos we offer.

If you’re reading this via RSS or email you’ll likely need to click through to the website in order to see the video. Enjoy!

If your Internet connection is struggling today click on the button that says “HD IS ON” to bring up a smaller video that will likely play better.

No matter if business is good or bad one thing is for certain… you, and those you work with, should be laser focused on cost reduction.

Now be honest, when you read the words cost reduction was the first thing that popped into your mind reduction in force? You know, laying people off?

Sadly this seems to be the most popular way to reduce costs for a lot of companies. But it doesn’t have to be this way.

There are so many other ways to reduce operating costs. So many one could write a 6 book series on the topic!

But until then, I’d like to propose 3 practical ways you and your organization, no matter the size or number of employees, can reduce costs in the front office.

Let’s get started.

1. Change Default Printing to Black & White

It’s estimated that it costs .08 cents a page to print in color versus .007 cents a page to print in black and white.

So, if we assume a person prints 10 pages a day x 260 workdays… printing in color will cost $208 per year while printing in black and white will cost $18.20 per year for a difference of $189.80.

Take that across a company of 5,000 employees and we’re talking some serious costs savings folks ($949,000).

There are ways to change the “default” print color to black and white on your computer to make this change happen. Your IT department can likely do this remotely, across the board, without employees having to do anything.

2. Text Messaging Plans

Next, if your company pays for associate’s cell phone usage I’d encourage you to check out the text messaging plans.

Some people are text message crazy while others are not. For those who love the text message it makes sense to have them on a plan to accommodate their usage.

But for those who rarely text it may make sense to have them “pay as they go” which can save $10 to $20 per month.

Again, taken across a company of 5,000 employees we’re paying a person’s salary ($100,000).

3. Print on Both Side of Paper

I have worked with clients who “recycled” their paper by printing on both sides.

They had special bins that employees placed their one sided printed documents into. This, printed on one side, paper was then placed in a special printer that everyone was mapped to.

This was their so-called “junk” printer… meaning if you wanted to print out an email or some other document that didn’t warrant a completely clean piece of paper the junk printers were called upon.

Depending on where you buy your paper, 500 sheets can cost up to $10. So, to be sure, this adds up quickly.

What am I missing?

Obviously this is a very short list of 3 things any company can do to save money. There are more posts I have written below in the Related Posts section for some additional ideas.

But I’m curious, what things are you and your organization doing to save administrative money besides, gulp, the lay-off approach?

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?

We lean advocates often talk about going to gemba, or the place the work is done, in order to see what is actually happening.

We also refer to the process of walking in order to seek out waste as going on a muda walk. Muda, for those that don’t know, is the Japanese word for waste.

This is great. Seeking out waste (i.e. motion, waiting, transportation) is important. Very important.

But, believe it or not, it is far from the most important thing you can do during a muda walk.

No, the most important opportunities you can seek out during muda walks are safety issues. You see, without a safe working environment nothing else matters. Nothing.

So, if you don’t already do this, be sure to keep a look out for any and all safety opportunities during your next muda walk.

Here’s a short list of 5 things to keep a look out for.

• Personal Protective Equipment – Are all associates, including managers, wearing the correct PPE? The requirements will vary by industry but some of the most common PPE are safety glasses, hard hats, ear protection, and gloves.
• Cheater Bars – In most situations the use of “cheater bars” or short pipes placed onto the end of a wrench or tool in order to increase leverage are not safe and shouldn’t be used. There are ways to make this safe – such as to permanently attach extensions made of common materials.
• Electrical Hazards – Your local safety experts will be able to guide you on the specifics for your location… but if you ever see 12 electrical extension cords tied together chances are you’re witnessing a serious safety hazard. Likewise, any other electrical safety concern should be addressed immediately even if it means stopping production.
• Machine Guarding – Make sure all machine guards are in place and functioning correctly. Often times machine operators will defeat safety interlocks in order to speed things up. This is very dangerous and can lead to serious problems – including death.
• Ergonomics – One of the most common reasons for back injuries and muscle strains is improper lifting. So, if you witness employees lifting more than they should be – or using a poor lifting technique – be sure to coach them, and the entire workforce, accordingly.

What else?

Do you seek out safety opportunities during your muda walks? If so, what things do you look for?

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?

What happens when 3 passionate lean proponents, one of which is a future US Senator, come together on a radio show?

To find out please have a listen to the recorded podcast of my first ever radio appearance, which was an absolute blast!

Also, if you have any ideas on how Yokoten can be applied across states (and the world) as Paul, Karl, and myself talk about towards the end of the podcast please comment below.

I’m very excited to announce that I’ll be on the Lean Nation radio show tomorrow, Friday, April 23 at 4:00 PM EST (3:00 PM CST) on 790 AM Talk and Business, hosted by Karl Wadensten.

We’re going to discuss many things… including lean, this blog, and Gemba Academy. Anyhow, I am totally excited as this will be my first radio appearance ever… being honest, I’m a bit nervous as well!

You can listen live on 790AM (Citadel Broadcasting, ABC Affiliate) in Providence, RI. The show is also globally available via a live audio stream at 790business.com so you can listen on your computer as well.

I would love to hear your opinions and answer your questions, so feel free to call in to the show. The call-in number is 401-437-5000 or toll free at 888-345-0790.

The podcast will also be available after the show.



We’ve received several questions related to how to calculate Process Cycle Efficiency (PCE) over on our most popular blog article of all time: How to Create a Current State Value Stream Map.

And while I have written on this PCE topic before… I decided to make a quick tutorial on how I came up with the PCE of 0.15% in the example VSM used as the case study in the aforementioned blog article.

Here is the spreadsheet used in the tutorial.  As always, if you have any questions, please let me know.

If you’re reading this article via email or your RSS reader you may need to click over to the website to see the video.

My family and I recently took a road trip.  During a stop at a restaurant I came across this sign in the restroom (click picture to enlarge it).

I’m curious to hear your thoughts on whether you think this is a weak or strong control.

What do you think?