Thoughts and Insights from the Shop Floor
Hopefully that title got some attention. In Toyota Kata, Mike Rother frames a PDCA coaching process around five questions. The first three questions are: What is the target condition? What is the current condition? What problems or obstacles are preventing you from reaching the target? Wouldn’t it be wonderful if we could build a machine …
In my review of Toyota Kata by Mike Rother, I suggested that the staff-level practitioners who are embedded in almost every company that is “implementing lean” could put those practices to work immediately, even if it was not an ideal “top down” teaching process. This week I gave that a try. I was coaching a …
This week I am coaching a kaizen team in the first phases of implementing a process to respond to problems on the shop floor. They clearly understand the objective, and are working hard. The key is to keep them focused on working out the problem response process vs. getting distracted by the production problems they …
I have seen this topic come up in forums many times, and seen wide ranging responses. If I were to summarize them all, it would be “I’ll know it when I see it.” A couple of weeks ago I heard a great quote from a co-worker that puts things into perspective. I’m always ready to …
In a recent blog post, Why C level executives don’t engage in ‘lean’…, Steven Spear makes a really interesting observation. He cites two main reasons. 1) “Lean” is regarded as a tool kit. There has already been a lot written here, and elsewhere, on this fallacy and how it continues to be propagated. Spear’s most …
Another great insight from “Toyota Kata” by Mike Rother. We often think great problem solving means solving the problem, that is applying countermeasures, and we may even propose and apply several countermeasures in the hope that one of them will stop the problem. In contrast, in Toyota’s way of thinking, if the solution is not …
The idea of a continuous improvement culture, a problem solving culture, a kaizen culture, has been with us for decades. Ultimately it is what everyone says they want to create. Yet creating that culture remains elusive for all but a few. I have noticed that, generally, when people describe the culture they are trying to …
I am in the process of (finally!) reading Mike Rother’s great book Toyota Kata. The book has already gotten great reviews out there, and I am not going to contribute a lot more to that dialog except to say I think it is the first substantial addition to community knowledge about TPS since Steven Spear …
Bryan Zeigler has a great post on his “Lean is Good” blog site. Titled “Andon Calls and Muri,” he describes Toyota’s phenomenal capacity for responding to problems, and then takes us back to where the rest of us are with some really great questions: If it is physically impossible to answer every andon call in order …
“No… this is coaching. That means I talk, you listen.” Many years ago, those words began a 20 minute session that I can best describe as an “a** chewing.” The boss systematically went through all of the little notes he had been saving for over a year – like the fact that someone had commented …
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