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Creating Resistance As You Go (Don’t)

The role of “change agent” is actually a role of leadership.

Leading change is difficult work that involves changes in the norms, routines, working relationships, behavior within and between groups. It is required when a simple technical change either isn’t going to get the job done, or requires the above changes to work at all. Most (if not all!) of the “lean tools”* fall into the later: The process changes are straight forward, but making them work requires altering the habitual patterns of how people work together.

Before I dive into what works, I want to spend a little time on what doesn’t work.

The Bulldozer: Creating Resistance

Bulldozer climbing a mound of dirt.

A team had a challenge – the result they were striving to achieve – of getting a 2-3 week administrative workflow (that sometimes went longer) down to a consistent three days. Their target condition was a pretty good work flow that, by all accounts so far, could avoid a lot of delays (on the order of days and weeks).

The changes they proposed would eliminate a number of transfers from one department to another (which always means another queue). However it also calls for eliminating some long-standing work-arounds that involve filling out forms and passing them along by email. But now they have a new ERP system, and the intent has been that this work is done within that system.

Those forms are in another department’s process, and involve people who haven’t been involved (so far) with the work to date. (There are valid reasons for this, and yes, some of this could have been avoided by involving everyone from the beginning, but that isn’t the point of the story.)

A functional department manager set off a flurry of pushback through a series of emails that essentially said “This is the future” and exhorting people to get on board with the new process vs. defending the old one.

One of the tenants of an effective change agent is “Don’t work uphill” with the corollary of “Don’t create hills in front of you.” I call the opposite of this the bulldozer approach. Unfortunately, like the picture above, just trying to push things through tends to build up a mound of resistance in front of you.

What did we learn?

Rather than trying to engage the new idea as an experiment – “Let’s try this and see what we learn,” the change agent tried to use position power to push the idea through. He took an action, and had an (implied) expected result – that people would see the light and adopt the new process.. The actual result, though, was quite different than what was expected – they doubled down on their resistance.**

A scientific-thinking change agent (a.k.a “a leader”) is going to step back and assess. Why did I get the reaction I did? What triggered it? What are the values of this constituency that are being challenged? Most pushback comes from a perceived threat to something that is regarded as valuable.

Perhaps the current workflow solves a very real problem. Perhaps it is otherwise very useful for something I am not aware of. Or maybe there is some emotional stake attached to the status quo. There is likely a combination of all three, or other factors I haven’t mentioned.

When proposing a new idea there is an opportunity to become curious about what previously hidden (to us at least) obstacles have just been uncovered, step back and work on the next one.

Leadership is a series of experiments. Not everything will work. But everything is an opportunity for learning and adjusting or adapting the next step appropriately.

People who expect their position-power to carry them through often tend to assign blame to individuals as “resisting the change.” But if we carry a different assumption – that everyone is doing the best they can to do the best job they can – then we can reframe and possibly reinterpret the reaction we are getting.

What other interpretations could we assign to this pushback other than “They don’t want to?” How many of those interpretations can we think of?

What is your next step or experiment?

Each of those possible interpretations is a testable assumption. Now I can frame my next action, conversation, or intervention to test one or more of those assumptions. This requires me to go into curiosity mode, because I really don’t know if they are true or not.

Now I have a different conversation because I am seeking first to understand. I can test assumptions without threatening anyone. Listen. Don’t defend. Paraphrase back until you hear “That’s right” signaling agreement that you heard what they were saying. That doesn’t mean you agree, but that you heard. Until someone feels heard they aren’t going to be soaking in what you are trying to tell them, they are going to be setting up the next defense of their position.

There is VERY rarely a need to directly confront someone over a different interpretation of the facts.

Don’t be a bulldozer – it doesn’t work.

———–

*And Six Sigma tools, and Theory of Constraints tools, and TQM Tools, and the tools associated with pretty much any other “program” that falls under the umbrella of continuous improvement.

**Though, Dr. Phil’s coaching would probably be something along the lines of “What did you THINK would happen??” (Semi-apology to my non-US readers who may not have context for this attempt at cultural humor.)

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Scientific Thinking vs. The Scientific Method

My recent post, “…but where is the problem solving?” stirred up quite a bit of conversation and traffic. I would like to dig a little deeper into what “good problem solving” actually looks and sounds like – beyond the forms and tools.

Underlying all good problem solving is scientific thinking. With it, I am constantly comparing what I think with what I observe, and looking at differences as evidence that what I think might need revision.

Some years ago, I was driving down a residential street in Rochester, New York, and observed a series of signs in a yard, each with a single number on them.

Huh… what are those? Maybe they are the house number. (Hypothesis) I checked the mailbox across the street, and saw the next number in sequence, the neighbor’s mailbox had the same as had the next number after that. (Devise a test of the hypothesis, run the experiment, gather evidence.) I concluded that, yes, the signs were indeed just the address displayed in a creative way, and continued my drive.

I didn’t run any formal experiments. I didn’t document anything. I didn’t go through “the five questions” – I just thought about what those numbers might be, and tested my thinking. Had the house numbers across the street been totally out of sequence, it would have remained a mystery, as my hypothesis would have failed.

Was I applying the scientific method? Not really. I applied all of those “hypothesis” terms after the fact as I wrote this. But at the time I was curious about something (the first step of science), and applied simple logic to test an assumption I had made. While it might not be “the scientific method,” I would contend this was “scientific thinking.”

Most of the time, that is my habit. When I am uncertain and curious about something, I check it out. I apply the same thinking pattern troubleshooting my computer when it does something surprising (or annoying – are you listening, Microsoft?). None of this rises to the level of formal experimentation, it is just methodical thinking.

More difficult problems require more rigor and structure. But many “problems” just require a pause, a little thought, trying something – followed by making sure it works – and moving on. It is the “making sure it works” part that many people leave out of this process. And it is “making sure it works” that raises a blind fire-and-forget action item into an experiment… assuming that if it doesn’t work, you then dig in to understand why.

Most of these things are quick and need little formal structure. People call them “applying common sense,” and I agree – as long as the experimental mindset is there.

Much like that previous post, some of us continuous improvement people have built specific expectations about what “problem solving” should look like. But, no matter what structure is applied, the underlying pattern of thought remains the same – even for casual troubleshooting.

It is this habitual pattern of thought that Mike Rother’s Toyota Kata is intended to teach through practice. He introduces structure, but any logically and consistently applied structure will work.

Let’s not confuse specific jargon or forms with our underlying intent: Learning to habitually glance across the street at a mailbox if you think those signs might just be the house number.

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How Does the Teacher Learn?

In my last post, If the Student Hasn’t Learned…, I made the point (again) that sometimes trying too hard to impose a formal structure on a learner can impede their progress.

Since writing that, I have been doing a bit of reflection on my own development as a coach, and I need to give credit where it is due.

As any regular reader knows, I have been an enthusiastic student and practitioner of Mike Rother’s Toyota Kata since I first read the book. I have written extensively about it in this forum. And I have made my own modest contributions to the practice. It has been over this time, and countless cycles of guiding beginning (and intermediate, and expert) learners through The Five Questions that I can hold the structure in my own head while not imposing rigidity onto others.

I will always default to using the formal structure because I think, in the vast majority of cases, it sets a better foundation. And even in those cases where I have to let go of the structure, that is a temporary countermeasure.

Once my learner is comfortable with the meta-patterns, then the structure follows, and makes sense to them. Some people learn that way, and I have to be able to pick that up.

I may have been an OK coach before all of this, I likely overestimated my ability at the time. Today, though, thanks to the Toyota Kata structure, I am becoming more comfortable with… not letting go if it, for I hold it in my own mind, but maybe withholding the framework and letting the learner fill it in more fluidly.

As we are boring down on the 10th Anniversary of Toyota Kata, and the 5th KataCon, we have a great opportunity to look at how the pattern that Toyota Kata teaches reaches far beyond process improvement and problem solving.

I will be speaking on the topic of Developing Leaders for Continuous Improvement on Day 1, and yes, we can use the same meta-patterns. Craig Stritar and I will be taking a much deeper look into the same principles in our Experiential Workshop. If you want to get a hands-on, reflective look at meeting your challenges as a change agent, come join us there.

In reality, the teacher learns by sharing and swapping experiences with others. I am not going to try to list everyone you will, and should, meet at KataCon here because I would surely leave someone’s name off my list by accident. But look at the presenters and speakers. I know most of them and were I not presenting my own workshops and breakouts, I would be hard pressed to decide which ones to attend. You can’t make a mistake here.

 

 

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If the student hasn’t learned…

… the teacher hasn’t taught.

Do you regard the structure of problem solving as dogma, or as an experiment with a predicted outcome?

If the learner struggles to master the structure, sometimes it is more valuable to find a different structure than to double down on what clearly isn’t giving the predicted result.

The Problem

Early this year I started work with a new client. They were trying to “implement A3,” and as I began to work with them, especially the new-in-the-position C.I. manager, I found they were struggling with what to write in the blocks of the “form.”

Of course there isn’t an A3 “form.” The A3 takes many configurations as the problem solver sets out to share the narrative with her coach. Nevertheless, beginners tend to find a format online, and work to put the right information in the various blocks.

In this case, my impression was that the blocks were getting in the way. “What should go in here?”  “What goes in the next block?” I didn’t really make a deliberate decision here, but I’ll tell you what I ended up doing:

What I Tried

First I tried the Toyota Kata format. He really liked that approach, but ultimately in this case we ran into the same kind of struggle. “Getting the structure right” seemed to be obscuring the bigger picture of the underlying thinking.

So I tried something more drastic: I let go of the format and the structure. Instead, let’s work on solving problems.

Like all organizations, there was no shortage of problems to practice on. So we just picked one.

Without the form, I had him map out the basic process steps. Then what happens, then what happens. What, exactly, is happening here. “The part is dropping off the conveyor.”

“OK, that’s the outcome, but what, exactly, is the mechanism that causes it to drop?” Describe what is happening. Draw it. Write it down. Show me.

After working to see process steps, we took on some pervasive quality issues.

“How is it even possible to produce this defect?” What are the steps involved to make a defective product? Yes – making defective product is a process, just like making a good product is a process. It is just a different process. What is actually happening here?

There were trials, experiments, measurements all with the goal of learning more, digging deeper, until the mechanism of the failure could be described. “This is what is happening.”

OK – how could that happen? Always forcing the discussion toward what is actually happening vs. what is not happening. If there was more than one possible mechanism to cause the problem, then “Based on the evidence we have, which of those can we rule out, and why?” Look at what’s left as a possible cause.

Of those, what trial can we run to see if we can rule that one out, or keep it in play.

At the end of a few of these, his language started to shift. He started speaking to others differently. He was learning to coach in different ways. He started asking different questions, boring in on the details with the intent of inquiry and dialog vs. “showing what I know.”

Oh – and he cracked a couple of chronic problems.

Then when the Corporate C.I. guy started insisting on “using A3” it was a pretty simple transition – it is just a way to describe what you know, what you do not know, and what steps you are taking to deepen your understanding because…

“The root cause of all problems is ignorance.”

– Steven Spear

What I Learned:

A core prerequisite to continuous improvement is good daily management of problem solving that applies solid scientific thinking to find the answers.

Once that thinking structure is in place, it can be expressed many ways, and A3 is but one of them. It isn’t the only one. As the level of scientific thinking deepens, the more the various tools and structures simply become fluid extensions to make it easier to express.

Sometimes I have found that if I try to force a particular format into place, I can end up having a container without any content.

Now… to be clear, there are many instances where the structure facilitates learning. It is just that in this particular case, the structure got in the way.

Asking whether learning is actually taking place, rather than trying to force a specific structure into place, may well be the difference between trying to teach by rote vs. staying focused on what the student is actually learning.

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…but where is the problem solving?

An external auditor was being shown the wide use of improvement storyboards throughout the organization. He was very impressed by the daily experiments, the documentation of what was being learned, and the results being gained.

Then he said “…but they aren’t doing problem solving.”

Huh? It turns out that, to this person, “problem solving” means using very specific “problem solving tools” such as fishbone charts, Pareto diagrams, histograms, etc. Since he didn’t see those specific tools being used, “they aren’t doing problem solving.”

But they are solving lots of problems – and that was clear.

Another C.I. director had the same complaint: If they aren’t documenting things on an A3 in a specific format, then they aren’t solving problems, or at least aren’t solving them effectively.

People have been solving problems experimentally for thousands of years. There have just been other ways to structure and document the process. I don’t think anyone who has a clue about the process they used could say that Wilbur and Orville Wright were “not doing problem solving” yet there is not a fishbone or Pareto chart in sight. Nope, they just meticulously documented their experiments, their predictions their results, and were laser focused on the problem they were trying to solve.

image

Saying people “aren’t doing problem solving” while acknowledging that they are solving problems doesn’t make sense to me, but I have heard it a few times.

Instead of trying to force the creative process through a specific template, how about pulling out the template as a helpful tool when it might help get something unstuck. In other words, for the tool itself – Exactly what problem are you trying to solve?

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A Period of Reflection and Learning

Some of you have commented in back-channels that I have been pretty quiet for a while – both here as well as in regular correspondence. I’ve been in pretty heavy reflective mode for quite a while. I described it to someone as “I am learning faster than I can write it down right now – by the time I write something, I understand it in a different way and start over.”

A lot of that reflection has been around consolidating what I learned at from Rich Sheridan, James Goebel and all of the other Menlonians that I have the privilege to know now.

That work was punctuated, though not completed, by my keynote at KataCon last February (2018) where I followed Rich Sheridan and described my interpretation of the underlying meta-patterns that exist in pretty much any organization that we would call exceptionally good at what they do.

At the same time, another client (Thank you, Tomas!) introduced me to Ronald Heifetz and Martin Linsky’s body of work under the umbrella of “Adaptive Leadership.” From their model I think I picked out a fundamental failure mode of what we like to call “change initiatives” regardless of what tool set of operational models we are trying to deploy.

To learn more about this, I read (Note – these are Amazon affiliate links. If you choose to buy the book, I get a (very) small kickback at no cost to you.)

The Practice of Adaptive Leadership

Leadership on the Line

Leadership Can Be Taught

Teaching Leadership

Your Leadership Edge

and every paper and article I could find on the topic or about people’s experience. While doing this, I have tried out many of the teaching and coaching processes as well as applying the observation, interpretation and intervention skills in the course of my work. Those of you who participated in the Experiential Workshop that Craig Stritar and I put on at KataCon early this year were seeing the outcomes of this work up to that point.

My latest step was taking a three day seminar Your Leadership Edge from the Kansas Leadership Center in Wichita the 2nd week of August. The KLC’s model and methods are built on the Adaptive Leadership model. My intended outcome was to consolidate some of my understanding by getting the external perspective and participating within their structure.

The number one frustration of “change agents” out there is some form of “How to I get buy-in?” I know I have experienced that myself. It is easy when all of the constituencies and factions within the organization are well aligned on purpose and values. Not so easy when there are conflicts. I think the Adaptive Leadership model gives us an approach we can learn by practicing. It also mirrors the steps of problem solving / continuous improvement that are outlined in Mike Rother’s Toyota Kata. The context for action is different, but the process is the same: Learning what works through experimentation. That is the “adaptive” part of Adaptive Leadership.

This post is just some background around why I am pursuing this line of thought. As always, I write about things like this to force myself to improve my own understanding by having to explain them in the simplest possible terms. I am happy to have any of you along the journey with me, so subscribe or check-in or whatever and let’s see what we can learn.

Mark

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Software Rules

“Turn off the radio, Hal.”  “I’m sorry, Mark, I’m afraid I can’t do that.”

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A couple of months ago I got the news that my 1995 Toyota Truck with 280,000 miles on it would require an engine rebuild plus a bunch of other stuff I wanted it to continue to be a reliable daily driver and for trips to Portland, etc.

I’ll relate the reason I didn’t replace it in-kind with a Toyota Tacoma in another post.

So now, skipping over the rest of the story, I am the owner of a new Jeep JL Wrangler.

One of the things that has happened since my 1995 Toyota was built is the introduction of electronics into vehicles. My truck’s OEM radio had an on/off/volume knob and a station tuner, plus some presets. (And the optional cassette deck.)

Now I have a 7” touch screen with all kinds of features.

One of those features is a radio. But search as I might, I couldn’t figure out how to just turn it off. I could mute it after I started the vehicle. But no matter what settings I had, when I next started the vehicle, the radio dutifully came on. As a last resort, I went to the OEM “Help” page:

US Customer Service – Chrysler Brand Site

Brief Description: How do I turn off the radio?

Comments: Every time I start the vehicle, the radio comes on. How do I stop that from happening? I can’t see any setting to prevent this.

VIN: 1CHJXDG3Wxxxxxx

Mileage: 61

This is the response I got:

On Tue, Jul 10, 2018, 12:52 PM customerassist
<customerassist@chrysler.com> wrote:
Dear Mark,
Thank you for contacting the Jeep Customer Assistance Center.

Radio mode is the default when the radio is booted up. Sadly there is no option to adjust what mode the radio will start in when the vehicle is started.  This ensures the radio is in the correct mode to allow for updates each time the vehicle starts.

Thank you again for your email.  Should you require additional
assistance, or have any new information to provide, please reply to this email message or call 1-877-I-AM-JEEP (1-877-426-5337).
Sincerely,
James
Customer Service Representative
Jeep Customer Assistance Center
For any future communications related to this email, please refer to the following information:
REFERENCE NUMBER: 3xxxxxxx
EMAIL CASE NUMBER:  3xxxxxx

Well, that was interesting. To be crystal clear, James is doing a great job. It is obvious he read my original query, and he didn’t just send a cut-and-paste response that is all too common. Still… just to make sure I was understanding this correctly, I responded:

Perhaps I wasn’t clear about what problem I am seeking to solve.

I am looking for how to start the vehicle and not have sound automatically start coming out of the speakers. The system does not remember “mute” for example.

So far the only thing I have found is to tune the radio to an empty frequency.

I am certain there is not an intention to force the customer to hear the radio every time the radio is started.

And get a deeper, more personal, response back:

Dear Mark,
Thank you for contacting the Jeep Customer Assistance Center.

Honestly the radio tuned to dead air is the best solution for this
concern I have as yet heard.  I can confirm that this is in fact the way the radio was designed and it is most likely operating as intended.  The radio will start in radio mode and the volume will be set to mid range to ensure the kids do not leave it cranked up too high for you.

I also feel that they dropped the ball a bit on this one as the radio will default to radio mode even if you were using a connected device when you left the vehicle outside of radio mode.

I have recorded your comments on the file for further review and we thank you for the time and effort it took to bring this information to our attention.

Thank you again for your email.  Should you require additional assistance, or have any new information to provide, please reply to this email message or call 1-877-I-AM-JEEP (1-877-426-5337).
Sincerely,
James

James didn’t write design, spec, or write the software. It is clear from his response that if he did, it wouldn’t include this “feature.” And I think I can interpret his response to strongly hint that this isn’t the first time they have heard about this little issue.

So I am thinking now of the mission of Menlo Innovations and my friends there: “End human suffering in the world as it relates to technology.” Perhaps this doesn’t rise to the level of “human suffering” but – seriously?

Kudos, though to James at Jeep Customer Service for his empathetic response that shows he actually read my email.  So FCA – you got that part right. Now… let’s talk about the user experience with your software. Looking at the Jeep brand’s core values, “Freedom, Adventure, Authenticity and Passion” I’d say you came up a little short on the “Freedom” part – I just want to be free to turn of the radio.   😉

I promised I’d be writing about leadership and coaching at the end of last post. That is coming, I just wanted to get this one out of the “drafts” list first.

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HBR: Managers Think They’re Good At Coaching. They’re Not.

“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 that I had a cow lick in my hair one day many months ago, which was framed as “lack of grooming.”  None of this, of course, had anything to do with what had triggered the tirade. As I recall I had scheduled a meeting with a supplier over something that he had thought was more important. Needless to say, the guy didn’t have a lot of credibility with the group, as this was pretty normal behavior.

What Is Coaching?

While my (real life!) example may have been a somewhat extreme case, a recent HBR article by Julia Milner and Trenton Milner titled Managers Think They’re Good at Coaching. They’re Not offers up some preliminary research that supports the hypothesis in their title.

What they found was that what most managers described as “coaching” was, in fact, offering direction couched in the form of advice.

As an alternative, they offer up a definition of coaching by Sir John Whitmore:

“unlocking a person’s potential to maximize their own performance. It is helping them to learn rather than teaching them.”

I can see where it would be easy to argue about whether or not “teaching them” is actually different from “helping them learn” but I tend (these days) to come down on the side of seeing a big difference.

To quote from David Marquet:

“… they have to discover the answers. Otherwise, you’re always the answer man. You can never go home and eat dinner.”

And, indeed, I see the effect of managers trying to always be “the answer man” every day – even this week as I am writing this.

Milner and Milner conclude with this take-away:

coaching is a skill that needs to be learned and honed over time.

This, of course, is consistent with the message that we Kata Geeks are sending with Mike Rother’s Coaching Kata.

The challenge for these managers is the same as that posed by Amy Edmonson in a previous post, It’s Hard to Learn if you Already Know.

Learning to Coach

The HBR article lists nine skills that the authors associate with coaching:

  • listening
  • questioning
  • giving feedback
  • assisting with goal setting
  • showing empathy
  • letting the coachee arrive at their own solution
  • recognizing and pointing out strengths
  • providing structure
  • encouraging a solution-focused approach

Unfortunately just memorizing this list really isn’t going to help much, because there are effective ways to do these things; and there are ways that seem effective but, in reality, are not.

The question I would like to examine here is how practicing the Coaching Kata might help build these skills in an effective way.

I’m going to start with the second from the last: Providing structure.

The very definition of kata implies a structure. Especially for that critical early practice, the Coaching Kata and Improvement Kata provide a mutually supporting structure for both the Coach and the Learner to practice building their skills. The Starter Kata that Mike Rother describes make up the most rigid form of that structure with very specific activities designed to push problem solving and coaching skills.

As the organization matures, of course, that structure can shift. But even very mature organizations tend to have “the way we do things” which provides a safe structure that people can practice and experiment in. Ironically, this is the very purpose of standardization in the Toyota sense.  (This is very different from what most organizations think of as “standards” – where experimentation is forbidden! )Without this baseline structure, sound experimentation is much more difficult.

Continuing to skip around on the list, let’s look at assisting with goal setting.

The very first step of the Improvement Kata is Understand the Challenge or Direction. Right at the start, the coach must assist the learner with developing this understanding. At the third step we have Establish the Next Target Condition. Here, again, the coach practices assisting the learner to develop a target condition that advances toward the challenge; is achievable; and is challenging.

While novice coaches can struggle with this, the structure of the Improvement Kata gives them a framework for comparison. In addition, the learner’s progress itself becomes data for the coach’s experiments of learning.

Of course questioning is the hallmark of the Coaching Kata. We have the “5 Questions” to start with, and they provide structure for not only questioning but listening as well.

There is a critical difference between giving feedback and giving advice, and beginning coaches – especially those who have formal authority – frequently fall into the trap of “leading the witness” – asking questions intended to lead the learner to their preferred answer. Giving feedback, on the other hand, might be more focused on pushing a bit on untested assumptions or gaps in the learner’s logic or understanding of the chain of cause-and-effect.

Thus, someone practicing the Coaching Kata is learning to let the learner arrive at their own solution vs. leading them to one that the coach has in mind. These are all instances where a seasoned 2nd Coach can help by giving feedback to the coach about her process – working hard to avoid “giving advice” in the form of exactly what follow-up questions to ask. (Believe me, this is more difficult than it sounds, and at least for me, doesn’t get any easier.)

I am going to make an interpretation of encouraging a solution based approach and assume this means exploring the space of possible solutions with experiments vs. “jumping to solution” and just implementing it. I could be wrong, but that is the only interpretation I can think of that fits with the context of the other items on the list.

And finally are the softer skills of showing empathy and recognizing and pointing out strengths. I think it is unfortunate that these skills are typically associated with exceptional leaders – meaning they are rare. These are things I have had to learn through experimentation and continue to work on. But I think I can say that my own practice of the Coaching Kata has given me a much better framework for doing this work.

The Coaching Kata framework is certainly not the only way to develop coaching skills. We have been training effective coaches long before 2009 when the original book was published. And there are very effective training and mentoring programs out there that do not explicitly follow the Coaching Kata / Improvement Kata framework.

BUT I will challenge you to take a look at those other frameworks and see if you don’t find that their underlying framework is so similar that the difference is more one of semantics than anything else.

In my next few posts, I am going to be parsing a course I recently took that is just that.

 

 

 

 

 

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Problem: What Does Maintenance Cost?

Another interesting “homework problem” showed up in the searches today:

an assembly line turns out parts at the rate of 250 per hour. on the average, the line must be shut down for maintenance for 20 hours during a month. how much production is lost each month?

Answer: None.

Wait a minute!! What about the 20 hours * 250 units / hour = 5000 units? Isn’t that lost production? Maybe. What problem are you trying to solve?

I’m making a couple of assumptions here. First is around the word “maintenance” vs. the word “repair.” If the line requires 20 hours of maintenance to run reliably and avoid repairs, then this time must be planned into the expected monthly production. Thus, no planned production is lost.

If no production above the planned level is required, then I can’t say any is lost. This is why one-dimensional questions like this are so dangerous. Whenever we are confronted with questions like this, we must always ask another:

Compared to what?

What should be happening? What is normal? What is needed? Simply saying that the line (when it is running) can produce 250 units per hour is data, but it gives us nothing to act on.

Here is the rule I have been pushing lately:

Whenever you measure something, there are always two values.

  1. What you measured.
  2. What is required or expected if the process or thing you are measuring is problem free or otherwise doing what it should or what you expect.

This is equally true for an observation.

  1. What you saw.
  2. What you should have seen if things were as expected or problem-free.

Then you can start the process of meaningful inquiry.

If my line produces 250 units / hour when running problem-free, and requires 20 hours of maintenance a month to be able to do that, we have a single piece of information: How much production I should expect during the month.

Is that enough? Then no problem, turn your attention to something more pressing.

Is that not enough? OK – now we have to get serious.

A lot of management teams confronted with this problem are going to reflex to just allocating fewer hours to maintenance in order to get more hours for production.

Don’t do it.

Just cutting maintenance time is going to make things worse. Maybe not this month or even next, but sooner or later you will be losing a lot more than 5000 units of production / month. What will make this frustrating is you won’t lose them all at once. You will experience slowdowns, short stoppages, jams, and all of these things will seem like a normal day – only you won’t be making 250 units per hour anymore.

This is where a lot of management team struggle. They only look at “maintenance hours” and issue a directive to cut those hours.

But “maintenance hours” is a metric that you cannot action directly. This is a classic example of what I wrote about a couple of years ago in “Performance is the Shadow of Process.”

Worse, this is a step away from what you are trying to accomplish… which is what?

Key Question: What Problem Are You Actually Trying to Solve?

“I need to reduce the time we spend on maintenance.” is not a problem. It might be a desire, or a possible solution, but if you start here, you are already restricting your thinking.

If you did reduce the time you spent on maintenance, what would you be able to do that you can’t do today? Why is this important to work on?

(Sometimes I get “We wouldn’t spend so much time on maintenance.” I always have to laugh when I hear something like this. Aren’t circular arguments fun? “OK, why is it important to spend less time on maintenance?”)

After some discussion, we might arrive at something like a need to produce another 1000 units / month to meet increased sales demand.

That becomes our challenge. Then the fact that we spend 20 hours / month doing maintenance is part of (and only part of) the current condition. But I can ask other question now such as:

How fast must we produce (units / hour) to get another 1000 units / month? You would be surprised how often the math tells us a number that is slower than “250 units per hour.” Huh. So maybe that’s the rate when things are running smoothly… where is the time going?

The point is that it is critically important to understand why you are asking how much time is being “lost” to maintenance to avoid jumping to a solution.

 

Poster - What Problem are you Actually Trying to Solve?

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It’s Hard to Learn if you Already Know

In this TED Talk, Amy Edmondson of the Harvard Business School talks about “How to turn a group of strangers into a team.” Although long-standing teams are able to perform, our workplaces today require ad-hoc collaboration between diverse groups. The question is: What kind of leadership, and what kind of structure, contributes to working together on the problem?

For those of you unfamiliar with her work, I’ll add that I have found anything that she writes or speaks about is worth reading or listening to.

The key message starts around the 10:00 minute point:

“When teaming works, you can be sure that leaders, leaders at all levels, have been crystal clear that they don’t have the answers. Let’s call this ‘situational humility.’ It’s appropriate humility. We don’t know how to do it.”

[…]

“It’s hard to offer up an idea that might be a stupid idea if you don’t know people very well. You need psychological safety to do that. They overcame what I like to call this basic human challenge: it’s hard to learn if you already know. And unfortunately, we’re hardwired to think we know. And so we’ve got to remind ourselves – and we can do it – to be curious; to be curious about what others bring.”

Here is the entire TED talk. If the embed isn’t working for you, this is the direct link: How to turn a group of strangers into a team.

 

 

 

Which brings me to the quote I pulled for the title of this post: It’s Hard to Learn if you Already Know. As Amy Edmondson points out, “we’re hard wired to think we know.”

To counteract this we need to construct different artifacts that focus our attention on our shared understanding vs. trying to advocate a particular position.

Creating The Structures of Teamwork

As obvious as this is when we say it, if we want to create a culture or social structure of teamwork this must be done deliberately. This is especially important in environments where ad-hoc groups must collaborate very quickly. So… what works? I don’t know. But we do have the tools to figure it out.

Structure to Focus on The Problem

When two people are talking about a problem while looking at each other, they tend to equate “the problem” with “the other person.” Rather than trying to reach a shared, common understanding, the tendency is to try to convince the other person to adopt their point of view.

But if we introduce some kind of artifact – an A3, a Learner’s Storyboard, a shared keyboard and monitor – that physically turns people to look at the problem rather than at each other, the dialog changes.

Collaboration at a shared keyboard and monitor

Collaboration at a learner storyboard.

“What we’ve got here is a reason to communicate.”

Think about the key difference between people looking together at the information versus someone at the front of the room, facing everyone else. The tone shifts from “tell me” to “work with me.”

Think of the key difference in a meeting between everyone sitting at the table talking about the problem vs. what happens if someone stands up and starts to draw it out on a whiteboard.

What companies like Menlo Innovations, Kaas Tailored, Toyota, and others do is construct physical artifacts to focus people’s attention away from the person and toward the information. The information becomes neutral, vs. being attached to someone. If something isn’t working, we can work together to fix the issue vs. fix blame.

The “Lean Tools”

Let’s take something as simple as standard work. What is it for?

One interpretation could be that I watch you perform the work, and if you violate the procedure, you fail the audit for not following the standard.

But the other interpretation is that we have a neutral point of comparison for how we think the work should proceed if it is problem-free. Seeing, or detecting any difference reveals a problem of some kind. We are invited by this information to look at the problem and seek to gain more understanding.

Of course, just sending an invitation doesn’t mean people come to the party. Shaping that conversation in constructive directions is what leadership is about.

And, as always, I write these posts mostly to clarify my own thinking by trying to explain it to someone else (you). I’d love to know what you think, so post comments!