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10 Books Every Continuous Improvement Practitioner Should Read in 2012

I hope everyone had a safe and happy new year and that things are off to an awesome start for you and yours!

To help kick off the new year I thought I’d share a list of the 10 books I recommend all Continuous Improvement Practitioners read in 2012.

I’d also love to hear your thoughts on books you recommend.

Finally, if you purchase any of the books below after clicking the links LSS Academy will earn a small commission. This helps us pay for site maintenance and hosting.

1. The Tipping Point

This is, without a doubt, one of my all time favorite books.

And while it may not be on every “book list” for lean and six sigma practitioners… it should be!

You see, in order for any “movement” to take hold you must find a way to get the idea to tip.

This books explains how to make that happen.

Amazon’s Description:

The tipping point is that magic moment when an idea, trend, or social behavior crosses a threshold, tips, and spreads like wildfire.

Just as a single sick person can start an epidemic of the flu, so too can a small but precisely targeted push cause a fashion trend, the popularity of a new product, or a drop in the crime rate.

This widely acclaimed bestseller, in which Malcolm Gladwell explores and brilliantly illuminates the tipping point phenomenon, is already changing the way people throughout the world think about selling products and disseminating ideas.

2. Outliers


Again, this isn’t your typical continuous improvement book… but it is a fascinating read on why some people succeed and some people don’t.

I especially loved the part of the book that explains how long it takes for someone to master a skill.

For example, do you know how many times the Beatles struggled before small pub crowds before making it big?  Gladwell tells the whole story.

Amazon’s Description:

In this stunning new book, Malcolm Gladwell takes us on an intellectual journey through the world of “outliers”–the best and the brightest, the most famous and the most successful. He asks the question: what makes high-achievers different?

His answer is that we pay too much attention to what successful people are like, and too little attention to where they are from: that is, their culture, their family, their generation, and the idiosyncratic experiences of their upbringing. Along the way he explains the secrets of software billionaires, what it takes to be a great soccer player, why Asians are good at math, and what made the Beatles the greatest rock band.

Brilliant and entertaining, Outliers is a landmark work that will simultaneously delight and illuminate.

3. Understanding Variation

If you work in the field of continuous improvement and haven’t read this book please do! It will change the way you approach attacking problems.

In fact, I will make the bold statement that this is the best book ever written on the topic of attacking variation through the use of control charts.

Buy 10 copies of this book and hand one to every practitioner you know.  They will thank you later.  I guarantee it.

Amazon’s Description:

We live in the Information Age, and much of that information comes to us in the form of numbers. But before numerical information can be useful it must be analyzed, interpreted, and assimilated.

Unfortunately, teaching the techniques for making sense of data has been neglected at all levels of our educational system. As a result, through our culture there is little appreciation of how to effectively use the volumes of data generated by both business and government. This book can remedy that situation.

Readers report that this book as changed both the way they look a data and the very form their monthly reports. It has turned arguments about the numbers into a common understanding of what needs to be done about them.  These techniques and benefits have been thoroughly proven in a wide variety of settings.

Read this book and use the techniques to gain the benefits for your company.

4. Kaizen: The Key To Japan’s Competitive Success

If I was only able to own one lean or kaizen related book this would be my choice.

In fact, my father gave me a copy of this book while I was in college. So, in fact, this was the first lean related book I ever read!

Kaizen: The Key to Japan’s Competitive Success was the first kaizen related book released in the west and will leave an indelible mark on how you think about kaizen in your workplace.

Amazon’s Description:

For the professional manager or student of management, a comprehensive handbook of 16 Kaizen management practices that can be put to work. KAIZEN uses more than 100 examples in action and contains 15 corporate case studies.

5. The Toyota Way: 14 Management Principles from the World’s Greatest Manufacturer

The Toyota Way is another must read for all continuous improvement practitioners.

Dr. Liker does a fantastic job of teaching lean concepts while also mixing in stories he learned during his time studying Toyota.

One of my favorite stories is how a Toyota Engineer drove a Sienna all over America in order to better understand how to improve its performance.  Talk about going to gemba!

Amazon’s Description:

In factories around the world, Toyota consistently makes the highest-quality cars with the fewest defects of any competing manufacturer, while using fewer man-hours, less on-hand inventory, and half the floor space of its competitors. The Toyota Way is the first book for a general audience that explains the management principles and business philosophy behind Toyota’s worldwide reputation for quality and reliability.

6. The Toyota Way Fieldbook


The Toyota Way Fieldbook is one of those books you will have highlighter marks and notes written throughout the book.

This book isn’t meant to be read one time… it’s meant to be absorbed and referenced again and again as you make your way through your continuous improvement journey.

Amazon’s Description:

The Toyota Way Fieldbook is a companion to the international bestseller The Toyota Way. The Toyota Way Fieldbook builds on the philosophical aspects of Toyota’s operating systems by detailing the concepts and providing practical examples for application that leaders need to bring Toyota’s success-proven practices to life in any organization. The Toyota Way Fieldbook will help other companies learn from Toyota and develop systems that fit their unique cultures. 

7. Taiichi Ohno’s Workplace Management


If you ever wanted to go inside the mind of Taiichi Ohno, the chief architect of the Toyota Production System, this is the book for you.

While this is a shorter read than the others recommended in this article it will not leave you disappointed.

This is another book worthy of handing out to every lean and six sigma practitioner in your organization.

Amazon’s Description:

This classic work by the founding father of the Toyota Production System returns to print in a new translation. Ohno delivers timeless lessons on how to effectively manage the gemba actual place or work. He relates stories from across his nearly 40 years of struggle to establish the Toyota Production System as both a mindset and supporting behaviors of constant improvement. In the book s 37 chapters, Ohno covers a broad range of topics and lays out the fundamental philosophy of kaizen (continuous improvement) that has made Toyota the most successful automobile manufacturer today.

8. The Goal: A Process of Ongoing Improvement


Three words best describe this book.  A true masterpiece.

I loved this book so much I not only read it multiple times… I also bought the audio book and listened to it!

In this book the late, and very great, Eli Goldratt takes us all on a fantastic Theory of Constraints (TOC) journey.

Amazon’s Description:

Written in a fast-paced thriller style, The Goal is the gripping novel which is transforming management thinking throughout the Western world. The author has been described by Fortune as a ‘guru to industry’ and by Businessweek as a ‘genius’. It is a book to recommend to your friends in industry – even to your bosses – but not to your competitors. 

Alex Rogo is a harried plant manager working ever more desperately to try and improve performance. His factory is rapidly heading for disaster. So is his marriage. He has ninety days to save his plant – or it will be closed by corporate HQ, with hundreds of job losses. It takes a chance meeting with a colleague from student days – Jonah – to help him break out of conventional ways of thinking to see what needs to be done. 

The story of Alex’s fight to save his plant is more than compulsive reading. It contains a serious message for all managers in industry and explains the ideas which underline the Theory of Constraints (TOC) developed by Eli Goldratt. Eliyahu M. Goldratt is an internationally recognized leader in the development of new business management concepts and systems, and acts as an educator to many of the world’s corporations. The 20th anniversary edition includes a series of detailed case study interviews by David Whitford, Editor at Large, Fortune Small Business, which explore how organizations around the world have been transformed by Eli Goldratt’s ideas.

9. Lean Hospitals: Improving Quality, Patient Safety, and Employee Satisfaction


While this book is definitely slanted towards those who work in the healthcare field there is much to gain for any lean practitioner.

Mark Graban, of Lean Blog fame, has crafted an excellent book that I highly recommend… especially if you work in the lean healthcare niche.

Amazon’s Description:

 Winner of a 2009 Shingo Research and Professional Publication Prize

Drawing on his years of working with hospitals, Mark Graban explains why and how Lean can be used to improve safety, quality, and efficiency in a healthcare setting. After highlighting the benefits of Lean methods for patients, employees, physicians, and the hospital itself, he explains how Lean manufacturing staples such as Value Stream Mapping and process observation can help hospital personnel identify and eliminate waste in their own processes — effectively preventing delays for patients, reducing wasted motion for caregivers, and improving the quality of care.

Additionally, Graban describes how Standardized Work and error-proofing can prevent common hospital errors and details root cause problem-solving and daily improvement processes that can engage all personnel in systemic improvement. A unique guide for healthcare professionals, Lean Hospitals clearly elaborates the steps they can take to begin the proactive process of Lean implementation.

The book has an accompanying website with more information.

Mark Graban was quoted in a July 2010 New York Times article about lean hospitals.

10. Beyond Strategic Vision: Effective Corporate Action With Hoshin Planning

I have read many books on the topic of Hoshin Kanri and, in my humble opinion, this one is by far the best of the bunch.

So, if you’re interested in learning more about Hoshin Kanri, sometimes referred to Policy Deployment, you’ll definitely want to read this one.

Amazon’s Description:

Hoshin is a system which was developed in Japan in the 1960′s, and is a derivative of Management By Objectives (MBO). It is a Management System for determining the appropriate course of action for an organization, and effectively accomplishing the relevant actions and results. Having recognized the power of this system, Beyond Strategic Vision tailors the Hoshin system to fit the culture of North American and European organizations. It is a “how-to” guide to the Hoshin method for executives, managers, and any other professionals who must plan as part of their normal job.


All Bleeding Stops Eventually

Here’s a fact you may not have realized… all bleeding stops eventually.

The key question, of course, is how long it takes to stop it.

Do we quickly apply a band-aid and limit the damage to our body or do we sit around and wait until medical attention can no longer save us?

I know it’s a gruesome thought – bleeding to death – but the parallels to problem solving are strong.

Let’s Create a Charter!

You see often times lean and six sigma practitioners identify an issue and prepare to solve it.

They form a team. They create a charter or begin an A3. They get approval to work on the problem. The have a kick-off meeting with donuts and coffee. And, finally, they start to identify root causes so a countermeasure can be applied.

This is all well and good… but the problem is the patient (the process in this case) is lying on the operating table bleeding to death!

Stop the Bleeding!

So, before you worry about forming your team or getting approval or planning a meeting… the most important thing you can do is STOP THE BLEEDING.

Apply a temporary solution/band-aid. Who cares if the solution isn’t perfect or ideal. All we’re trying to do is keep the patient alive.

Of course, once the bleeding has been stopped we must seek a more permanent countermeasure to the problem… in other words don’t relax once the band-aid has been applied. After all, that’s how disease and infection sets in.

Do you agree?

Do you agree with this approach to problem solving? Should we keep the patient/process alive by applying a temporary solution/band-aid?

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 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.

Farewell iSixSigma

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.

This is the worst it’s ever been

I’m typically a glass is half full kind of guy.

But I also believe the phrase ”This is the worst it’s ever been…” just may be the mission statement successful people and organizations live by. 

You see, while it’s good to celebrate that successful kaizen event, or securing that huge order, or even winning the championship game… individuals and organization’s that hope to succeed over the long term must never grow satisfied with where they’re at.

Instead, they must constantly realize that this is indeed the worst it’s ever been.  As such, there’s only one solution… make it better.

Do you agree?

My Take on Lean and Six Sigma Certifications

A few days ago I posed the question about whether exam based lean six sigma certifications were legitimate or frauds.

As usual, many of you came through with excellent thoughts and comments.

Some of you supported the idea, others argued against exam based certifications, and others maintained a neutral position.

Here’s my two cents.

Learning is Always Good

First of all, learning is always good.

It doesn’t matter if you read a blog article, book, or watch some handsome fellow wax poetic about lean on video… learning something new is never bad.

To Each His or Her Own

Next, people learn differently. At Gemba Academy we hear of how some folks love to read the PDF summaries of each lesson. Why? Because they like to read.

Other people prefer online videos, DVDs, in person lectures, or a combination of all these.

The point is everyone is different.

What about Certifications?

Now, to the question of certifications.

I am of the opinion that certifications can be good when approached properly.

And by properly I definitely feel some hands on project work should be done in addition to passing an exam.

The idea of completing a “virtual” project or no project at all doesn’t sit well with me at all as it flies in the face of going to gemba, or the place the work is done, to practice what you learned.

Certifications Means The World to Some

Many opponents of certifications live in the West where these types of things don’t matter much since higher education is the norm for many.

But I can tell you this… I have seen individuals from developing countries break down and cry when they received their certification… it meant the world to them.

So, it’s important to remember that not everyone has the same opportunities in life. As such, we should not be so quick to judge others and their accomplishments.

Problems with Certifications

With this said, certifications don’t come without their problems.

  • Resume Builder: Some folks simply approach certifications as a way to strengthen their resume. In other words, they don’t really care about what they are learning. They are only going through the motions to get a piece of paper.
  • One and Done: Another problem is the one and done… whereby someone completes the certification and never uses their knowledge again. Sad, but I have seen this many times, especially with green belts.
  • Elitist Attitude: Third, while not always the case, some certified folks become elitists… they feel like they are smarter and better than others. This flies in the face of respecting people, a pillar of authentic continuous improvement.
  • Learning Stops: Finally, certification sometimes leads to the person feeling as though there is nothing left to learn.  This is, obviously, never the case. 

Do Something

In the end… I come back to the story I wrote about before where my Grandpa was caught in the middle of a busy intersection… frozen with fear.

After a few seconds my Grandma, God rest her soul, finally yelled, “Well do something!”

It’s also like the question I get from my church friends on which version of the Bible they should buy.  My reply is always the same – the one you will read.

So, no matter if you choose to seek certification or not… I encourage you to do something.

In the end I really believe that if you constantly seek knowledge with a humble heart while working to help others… you will not go wrong.

What do you think?

What do you think of my perspective? Do you agree?

Exam Based Six Sigma Certifications – Legit or Fraud?

The topic of Lean and Six Sigma Certification is one of the most debated topics in the continuous improvement world.

And since I’m never one to shy away from some good old fashioned debate… I’d like to present the following scenario for discussion.

Specifically, Hayley, a reader of LSS Academy, asks the following question regarding six sigma certification:

How legitimate do you feel are Green Belt certifications which don’t call for a project submission and are examination based only? I am trying to get my team of 11 trained and LSS green belt certified, and am looking at all the available options for the best path to take.

Of course I see the need for real world application of the tools and theories learnt in training, however with no assessment standard for projects doesn’t it go against everything that LSS teaches us as far as being measureable and repeatable, to submit a project which one person may deem passable and another person inadequate and have that decision justify your accreditation (or not)?

Shouldn’t the exam show that you are competent at applying what you have learnt?

I will offer my two cents later this week… but I’m very curious to hear your thoughts. So what do you think? How would you respond to Hayley?

Join us for a Lean and Six Sigma Networking Party in the Seattle area!

Gemba Academy is sponsoring the next iSixSigma Live! Social and Networking Party in the Seattle/Bellevue area. If you live in this part of America please be sure to come out and say hi!

Here are the details of the event.

Join us for an iSixSigma Live! Social and Networking Party in Seattle/Bellevue!

This iSixSigma Live! event will unite and strengthen the Seattle-area community of business process improvement leaders at all levels.

What: It will be an after-work social event for all Seattle area quality professionals. We will have appetizers, an open bar, music, a pool table and the most exciting change agents from leading Seattle-based organizations. This is the one local event you don’t want to miss! Register Now!

Who: Attendees will include anyone involved or interested in process improvement.

This includes current and aspiring Lean and Six Sigma professionals, transformation leaders, continuous improvement professionals, business process management, process excellence, students… you get the idea.

Why: Do you need a reason to socialize? Ok, maybe you do. How about: professional networking, seeing old friends, building new friendships, finding peers for professional support, you’re a pool shark and you’re looking for easy targets, meeting Seattle’s top talent pool, having an excuse to leave the office by 5 PM.

When: Thursday, September 30, 2010 5:30 PM – 8:00 PM

Where: Rock Bottom Brewery
550 106th Ave
Bellevue, Washington 98004
(425) 462-9300

Cost: $30

Register Now!