The Hello Bar is a simple notification bar that engages users and communicates a call to action.

Total Productive Maintenace (TPM) Overview

If your company relies on machines and/or equipment of any kind to satisfy customer demand chances are extremely high that Total Productive Maintenance (TPM) could benefit you.

With this said, I’m excited to announce that Gemba Academy has just released their newest course focused entirely on Total Productive Maintenance, usually referred to as TPM.

In this course Mike Wroblewski, of Gemba Consulting and the Kaizen Institute, explains what TPM is, and isn’t, while also covering topics such as the 6 Big Losses and Overall Equipment Effectiveness (OEE).

With the release of this new course Gemba Academy now offers 160 lean manufacturing training videos covering topics such as The Kaizen Way, 5S Workplace Productivity, Dealing With the Seven Deadly Wastes, Practical Problem Solving, Standard Work, Leader Standard Work, Transforming Your Value Streams, The Seven Quality Control Tools, Quick Changeover: The SMED System, and Lean Lingo Explained.

Finally, here is the first video of the TPM course.   If you’re reading this post via email or RSS reader you’ll likely need to click through to the website to view the video.

Should we Pay for Performance? What do you think?

Dan, a reader of LSS Academy, recently emailed me this excellent question.  I was hoping to get your help as I formulated a response.  Here is Dan’s question.

Ever since I studied process improvement at BYU I learned about E. Deming and learned that he was a catalyst in the change that occurred in Japan.

One of Deming’s points or teachings is about rewards or pay for performance. Deming has been asked what the alternative is for merit pay increases and his response has been anything else would be better.

Well, that doesn’t really help me out. I am a supervisor for a manufacturing company and our current system of performance reviews and pay increases needs an overhaul. I have two challenges:

1. What is a better alternative?
2. How do I help my management buy into it?

Any ideas? Thanks for your help.

What do you think?

The Making of the 2010 World Cup Soccer Ball

I am coaching my daughter’s U7 soccer team this year and, as such, have been reading as much I can about the game.  I was a wrestler growing up… never played soccer in my life! 

Anyhow, I came across this video on how the 2010 World Cup soccer balls were manufactured.  It seems to be a mix of high tech automation and craft manufacturing. 

Check out the video below (RSS and email readers will likely need to click through to the site).  How would you change this manufacturing process if you were in charge of it?

3 Practical Ways to Immediately Reduce Costs

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?

Vague Instructions and Counting

On Monday I wrote a fun little article asking the fine readers of LSS Academy if they could count! Of course this was all done in fun… as I know you can all count.

But, as many of you pointed out, there were several lessons to be learned from this exercise.

Bad Instructions

It took awhile but my friend, and business partner, Jon Miller rightly pointed out that my “instructions” we poor at best.

You see, I mentioned “the next paragraph” but then the next paragraph was a sentence that contained no F’s at all. Or is it Fs? Jon always corrects me and my other business partner, Kevin, on the use of the apostrophe… but I digress!

The lesson to be learned is to make sure any and all instructions are crystal clear and leave no room for misunderstanding.

Loose Measurement Systems

Now, for those of you that focused on the large paragraph… well, how can I say this nicely? Some of you did better than others!

Truth be told I have done this experiment hundreds of times and before I posted the article I counted and got 27! So, yeah, I stink at counting too!

The trick, as many pointed out, is that for some reason we often miss the word “of” and thus totally screw up the count.

The lesson to be learned is it is very easy for humans to make mistakes. It doesn’t matter how educated you are and how careful you’re being… visual inspection of any kind is darn hard.

Error Proofing

So, perhaps, the best solution for difficult tasks like this is to use some form of error proofing… removing, or at least minimizing, the chance of human error.

Shaunak wins the prize for the most, um, creative idea with his idea of using Excel and a little formula. See his comment below if you’d like to give it a try.

Or, if you’re a bit simpler minded, like me, you could copy the text into MS Word and use the “Find and Replace” function and simply search for f.

When you do this you’ll quickly learn that F is used 36 times in this paragraph!

The lesson to be learned is to always seek a form of error proofing when the chance of human error is high.  You don’t always have to use technology to accomplish this but is some cases, it might help.

What do you think?

Were you surprised at how hard it was to count the F’s? If so, can you imagine how many mistakes are made each and every day as humans, who will make mistakes, visually inspect all sort of things? Scary isn’t it?

Can you count? Are you sure?

If you’ve ever gone through some form of continuous improvement training you may have done this little experiment.

But in case you haven’t, I’d like to challenge you to count the number of times the letter “F” (upper or lower case) is used in the following paragraph.

Post your guess, I mean answer, in comments section.  Ready?  Go!

The necessity of training farm hands for first class farms in the fatherly handling of farm live stock is foremost in the eyes of farm owners. Since the forefathers of the farm owners trained the farm hands for first class farms in the fatherly handling of farm livestock, the farm owners feel they should carry on with the family tradition of training farm hands of first class farmers in the fatherly handling of farm live stock because they believe it is the basis of good fundamental farm management.


The Rolling Tool Cart

I recently came across the video below and was intrigued by many aspects of this “rolling tool cart.”

Here are some of the things I liked.

  • It was made for around $50 according to this article.
  • It’s on wheels
  • It can be moved to point of use eliminating motion
  • It seems to be relatively safe to use
  • It doesn’t take up much space

Here are some things I think could be improved.

  • Do we really need that many tools on one cart or should we only focus on the tools we use most?
  • If something was missing would we know?
  • While labels are not everything… I’d at least like to see the drawers labeled.

What do you think?

What do you think of this?  Thumbs up or thumbs down?

Bill Waddell on American Manufacturing

I don’t pretend to be an “economic guru” by any means… honestly it all makes my head hurt a bit.

I did, however, thoroughly enjoy reading Bill Waddell’s thoughts on the state of manufacturing in America – and really the West in general.

Bill, for those that don’t know, may have forgotten more about manufacturing than many of us will ever know.  He also writes over at Evolving Excellence and is, um, passionate.  Yeah, passionate is a good word.

I’ll also warn you ahead of time, Bill is an opinionated fellow… but seems to have a tremendous amount of wisdom that I, for one, have personally learned from.

If you’d like to download and read Bill’s rant, I mean thoughts, visit his website and download the Word document titled “The Hollow American Economy.”

After you read – or at least skim the paper – I’d be interested in your thoughts.  Specifically, do you agree with Bill?  Or do you think he may be missing the mark?

Free Introduction to Lean Video

Here is part one of our first Gemba Academy video. To see the complete and full screen version – in high definition – please visit our main site. Stay tuned for more free videos in the coming weeks.

The Best Investment Advice

Note: This is the 400th article here on LSS Academy! I’ll take some time to reflect on this in the near future. But for now, I have a far more important topic to discuss. Read on.

Times are tough. Real tough. You may have recently lost your job. You may be worried about losing your job. You may be worried about making payroll this month. No matter the situation you’re in… chance are… things have been a lot better than they are now.

What to do? I’ll tell you exactly what I think you should do. Invest. Yep, that’s right. You and I need to invest like never before.

And before you think I’m crazy I am not proposing you invest in the stock market, housing market, or anything like that.

Nope. I am talking about investing in two particular things – yourself and your company.

Invest in Yourself

Let’s begin with you. Here are some tips for how you can invest in yourself.

  • Make something happen. You have the knowledge. You have the will. Now it’s time to do something with these attributes. Go to your gemba – or the place the work is done – and attack the waste that’s devouring your company. It’s there. I promise. Find it… then kill it.
  • Learn something new. I don’t care what it is. Learn something new and learn it this week. Need help? Click here.
  • Help others. I assure you someone has it worse off than you. Find them and help them. You’ll help yourself more than you know.
  • Stop worrying. Lastly, worrying is natural. It’s also detrimental to success. So try to stop worrying and instead start focusing on the three points above.

Invest in Your Company

Now that we have you taken care of let’s switch gears and talk about how you can invest in your company.

  • Run a kaizen. Find something to improve. Assemble a team. And hit it. And hit it hard. Then when you’re done – repeat.
  • Light the fire. Ever heard of the burning platform? Now is the time to light a few while pouring gasoline all over them (metaphorically speaking of course).
  • Ask how you can help. Not sure what you can do to help your company? Ask someone. If they don’t know ask someone else.

What about You?

Do you agree with this advice? If so, why? If not, why? Do you have anything to add to the ideas above?

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