This category contains 83 posts

Stop Jumping to Countermeasures

As strange as it may seem, one way to get people to correctly follow a PDSA-based problem-solving process is to convince them to forget much of what they know and approach at least the early steps in the process as if they don’t completely understand the situation. Continue reading

No Systems Thinking in Trump’s Plans

Another difficult to quantify consequence of significant tariff increases is the effect on developing nations that rely on access to the U.S. market to continue growing. The administration wants to build a wall along the U.S.-Mexican border to keep people from crossing into the U.S. illegally. Since many of those coming into the U.S. from Latin America do so for economic reasons, raising tariffs and pressuring manufacturers to scrap foreign factories to build in the U.S. will result in lost jobs and other problems for those countries. It seems logical then, that this action could actually increase the number of people attempting to cross into the U.S. to escape poverty. Continue reading

Improving Dashboards With The 3-Meter Rule

Dashboards are critical for a successful continual improvement effort.  Effective dashboards can drive better coaching, faster team meetings, and more effective problem-solving.  A common problem that interferes with the effectiveness of dashboards, however, is the inclusion of charts that attempt to convey too much information and are difficult to understand.  One way to prevent this … Continue reading

Identifying Proper Leading Metrics

The problems people have related to identifying leading metrics often result from failing to connect the effort to problem-solving. Attempting to determine the proper leading metrics in isolation from problem-solving often leads to frustration and wasted effort in creating and maintaining the measures, and a lack of clarity in understanding how to improve performance of lagging metrics. Continue reading

There’s No Generalizing in Lean

It has been decades since we first learned about the Toyota Production System and how it contributes to the company’s quality, productivity, and competitive success.  And although some companies have done very well with lean, most have struggled.  There are many reasons for failed applications of lean, but one that gets very little attention is the … Continue reading

Are We Happy With Mediocrity?

“Nobody gives a hoot about profit.  I mean long-term profit.  We talk about it, but we don’t do anything about it.” – W. Edwards Deming Why do so many companies seem to be happy with mediocre performance? People generally consider the idea of having it all – perfect safety, high quality, short cycle times, low … Continue reading

When Lean Fails

Many companies today are jumping on the lean bandwagon and expecting huge cost reductions as a result.  Unfortunately, many of these companies will never see the type of improvements they expect from lean, and their leaders will likely become disappointed and frustrated, and eventually abandon the effort. There are a number of reasons companies fail … Continue reading

A Simple a Process for Achieving the Vision

Determining the gap involves breaking down the vision, which is often stated as a generalization, into specific 3-5 year objectives (which often include targets for safety, quality, production/schedule, and cost, although other areas can be covered). The objectives are regularly compared to current performance to determine the gaps that needs to be closed to move the organization closer to the vision. Continue reading

I Already Know Lean

Although some people have more of an inclination toward lean thinking than others, everybody needs some level of learning or coaching to develop it more deeply. The conventional western approach to business over the last century runs so counter to lean that a deep level of reprogramming is necessary for most people. The problem for those leading the transformation, though, is to convince those who already do lean that, although they may apply components of it to their work, the big gains from lean come when it is understood and applied as a system. Continue reading

It is Too Easy to Fire People?

“I am convinced that nothing we do is more important than hiring and developing people.  At the end of the day, you bet on people, not on strategies.” – Lawrence Bossidy How effective is your hiring process?  How do you know? If it was difficult or impossible to fire people after you hired them, would … Continue reading