May 1, 2011 | Collaboration, Lean, Management, Operations
Process improvement is all about slow adoption of the tiny opportunities that arrive, by any number of means, that together enable adaption of the system to the environment around it to improve performance.
My favorite metaphors usually come from the natural environment, where natural selection enables minute differences over time to become different species.
In organisations we do not have the time, so the process needs to be encouraged, speeded up a bit. Experience suggests there are a few pre-conditions for success:
- There is a willingness to make change, and that willingness is shared through all levels of an organization.
- There is a willingness, indeed pleasure in embracing mistakes, as it is by making mistakes and understanding why the mistake occurred, that we learn.
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There is a coherent plan, strategy, budget, whatever you choose to call it, that provides a framework for decision making, performance measurement, and allocation of responsibilities in a transparent, ordered and consistent manner.
Apr 28, 2011 | Lean, OE, Operations
“Gemba” is a Japanese term, literally “the real place” and is a term used extensively in lean management, meaning, in effect, go to where it happens and look to understand. This originally meant the manufacturing floor, but just as easily translates to anywhere real work happens.
So often I see people doing dumb things, not because they want to, but because that is the way the process was designed, usually by someone who had not done a “gemba walk” but who had relied on a model that seemed sensible for some reason, but bore little relationship to the way things worked in real life.
Most things I see that lead to problems are caused by self indulgence, ego, and isolation, not incompetence or lack of care, so next time, stop yourself, and do a “gemba walk” to see how the users will interact with and use whatever it is you are designing.
Apr 7, 2011 | Collaboration, Leadership, Lean
Management structures have flattened and globalised at the same time, radically changing the way collaboration happens. Now virtual teams work across all sorts of boundaries, and have created a new set of challenges.
Traditional management simply does not work effectively, so new sets of behaviors are evolving to enable virtual teams to be managed, and to manage themselves. The tools all revolve around mutual obligation and trust, a recognition that the direct and control management style has outlived its usefulness, and it is the outcome of the team activity that is important, not necessarily the way you get there.
The foundation of successful self and virtually managed teams is a very solid framework of shared objective, collaborative behaviors, and stable processes that can be continuously improved. Sounds easy, but it is very hard, and takes a long termview and great leadership to achieve anything worthwhile.
Mar 30, 2011 | Lean, Management, Operations
The clarion call for improvement, in everything from the minor shop floor activities to big picture strategic implementation is clear. We all need to do more with less, and this requires that we identify which bits of our current activities should be changed, redirected, or trashed.
In effect, there are three questions that should be answered:
- What are the underlying drivers or causes of problems?
- How can we build predictability of outcomes from any particular activity, and group of activities?
- How can we ensure the mistakes of yesterday are not repeated today?
These seemingly simple questions lie at the core of all improvement I initiatives.
Mar 28, 2011 | Lean, Operations
Another story about a US company going against the trend and “on-shoring” to shorten supply times, improve quality and certainty, and gain control over their operations.
Forward thinking companies in developed economies are starting to recognise that manufacturing is a foundation stone of innovation, that manufacturing really matters, despite the decades of being told it does not.
Previously, I have made the point that labor costs alone do not make the case for producing product off-shore, largely in China, and the message seems to be filtering through, as firms start to rethink and bring manufacturing home.
Labor costs are easily measured in the P&L, so can be cut, but time is not measured by traditional accounting, making cutting it a less obvious benefit to many, but if you ask a consumer when they want a product, the answer is usually “now”.
Besides, the bean-counters do not mind inventory, as it is in the books as an asset, not usually measured by cycle time, and the velocity of cash through a business. Not checking item level inventory and cash velocity through a business is like a doctor not taking your blood pressure and heart rate at in a check-up.
Mar 27, 2011 | Customers, Lean, Marketing
Last week I had a problem with my mobile internet connection when changing plans. Usually a simple process, something went array in the supplier, and I could not connect and as the “new improved” plan rolled into service, I had nothing, at a most inconvenient time.
I got onto the carrier, and their technical help desk fixed it quickly by stepping me through a process on my computer. All that is OK, but it seemed that the problem should never have been occurred, so fixing it quickly was good, but it was just bolting the stable door.
The following day I got a call from a researcher setting out to get my feedback on my experience with their techos. A very polite young lady, whose first language was not English took me though a series of 1-10 options ranging from outstanding to poor along a number of parameters, each sought measures of my experience with the technician. He scored very well. However, she did not have any questions about the cause of the problem, or how I felt about the fact that it happened, and when I tried to explain that my high marks for the tech assistance should not be confused with the dismay at having had the problem, it all got too much for her.
Customer service is all about preventing problems in the first place, when you cause them your customers are grateful that they were fixed, but will not necessarily forgive you for causing them. To be effective at improving service, they should have investigated the cause of the problem, so they could take steps to prevent it happening again, not check that an empty stable had been well cleaned.
