What Is “Lean?”

I did a Google search on the terms [ lean manufacturing definition ]   . Here is a smattering of what I found on the first page of results. (I did not go on to the second page.)

On the lean.org site we get a page with about 10 paragraphs describing the general outcome, philosophy, and what it isn’t.

On a consultant’s web page we get a list of principles and terminology definitions.

The U.S. Environmental Protection Agency (EPA) says “Lean manufacturing is a business model and collection of tactical methods that emphasize eliminating non-value added activities (waste) while delivering quality products on time at least cost with greater efficiency.”

Tooling U defines “lean manufacturing” like this: “An approach to manufacturing that seeks to reduce the cycle time of processes, increase flexibility, and improve quality. Lean approaches help to eliminate waste in all its forms.”

Another consultancy has a PDF of “Lean Sigma Definitions” that includes Lean Manufacturing or Lean Production: “the philosophy of continually reducing waste in all areas and in all forms; an English phrase coined to summarize Japanese manufacturing techniques (specifically, the Toyota Production
System).”

Let’s Rewind a Bit

What all of these definitions have in common is they are attempting to describe some kind of end state.

Over the last 10 years or so we (meaning those of us who are doing top drawer research) have put together a pretty comprehensive picture of how Toyota’s management systems are intended to work. (I say “intended to” because we are always dealing with an idealized Toyota. They have issues as well, just like everyone.)

What we seem to try to do is try to create a generic context-free definition of what Toyota is doing today.

But they didn’t start out that way. Everything they are, and do, evolved out of necessity as they struggled to figure out how to take the next step.

Toyota didn’t engineer it, so I don’t think it is something we can reverse engineer. Toyota evolved it organically. They applied a common mindset (a dedication to figuring things out) to a specific goal (ideal flow to the customer) in a specific set of conditions.

So What is “Lean?”

Mike Rother makes a really interesting attempt at resetting the definition of “lean” as being about the drive and the mindset that resulted in Toyota’s management system.

Give it a read, then let’s discuss below. (Since you are going to see it – when he sent it around for input, I passed along a thought which he has added verbatim in the last slide. Maybe that will spark a little more discussion.)

 

OK, are you back?

I like this because I think anyone who adopts the mindset that they (and I mean “they” as a true plural here) must take it upon themselves to figure out what they do not know, figure out how to learn it, figure out how to apply it, all in a relentless pursuit of perfect flow will end up with a nimble, empowering, relentlessly improving, formidably competitive team of people.

Focus on the process of learning, focus on the people, and keep them focused on the customer, and you’ll get there.

In my experience, the differentiator between organizations that “get there” and those who don’t comes down to the willingness to work hard to learn it themselves vs. wait for someone to tell them the answers.

Thoughts? Maybe we can take the “most comments” record away from the “Takt Time Cycle Time” post.  *smile*

Jeff Liker: Is Lean a Waste Elimination Program or Striving for Excellence?

Jeff Liker asks (and answers) the title question in a great Industry Week blog article by the same title.

One of the biggest obstacles we in the lean community need to overcome is our own inertia around “Lean is a process for finding and eliminating waste.”

In the article, Liker brings up a point that is often lost on us: Looking for the problems and negative things kills morale.

The “waste” that you see is the result of underlying issues and culture. Stop overproduction in one place, and it either returns or pops up elsewhere because the underlying reasons for it were never addressed.

Operations that are not operating at a high level of lean typically are lacking underlying process discipline, which leads to these problems and they proliferate daily as the company is in a constant firefighting mode. Trying to eliminate waste in the current system and culture is like identifying and fighting problems—it is debilitating and a losing proposition.

[Emphasis added]

I bolded that phrase for a reason.

We aren’t talking about a technical implementation here. We are talking about a shift in the underlying culture – the habitual ways people interact with one another, with the process, respond to challenges and problems.

Today we have, thanks to Jeff Liker and a few others, an excellent picture of an ideal version of Toyota. We know what it looks like.

Getting there is an entirely different proposition, as most companies that have tried this stuff know first hand. It is hard.

What is beginning to emerge, though, is that the thinking pattern that is learned through solving these problems the right way (vs. just implementing tool sets) is the same thinking pattern required to shift the culture.

It is hard. You have to do the work. But the way to get there is emerging.

David Marquet: Turn The Ship Around

A while back, Mike Rother sent around a link to a sketchcast video of a U.S. Navy submarine skipper talking about the culture change aboard his submarine, the USS Santa Fe. I posted and commented on it below, in “Creating an Empowered Team.” If you haven’t watched it, do so now so you have context for the rest of this post.

Since then, I found other presentations by Capt Marquet (pronounced, I have learned, “mar-kay”), read every post on his blog, then bought and read his book Turn the Ship Around.

His message is compelling, and I have been digesting and integrating it for a couple of months now.

The Empowerment Movement

Back in the late 80’s and early 90’s there was a big push for “empowerment” and the idea of “self directed work teams.”

Supervisors and managers were re-titled as “coaches.”

Work teams were told they were expected to self-organize to accomplish the work at hand.

I suspect this was yet another case of “benchmark and copy” – observing the attributes of high-performance organizations and trying get the same results by duplicating the description. “They have self-directed work teams, so let’s tell our work teams to self-direct.”

In the classic words of Dr Phil… “How’s that workin’ for ya?”

I have worked with, and in, a few organizations with a very bad taste for their past experiments with “empowerment.”

The Difference between “Involved” and “Committed” Leadership

Obviously some organizations have succeeded at creating work environments where work teams know what has to be done and do it. If that weren’t the case, there wouldn’t have been anyone to benchmark and copy.

Capt Marquet’s book gives us a first experience account of a leader who resolved to change the climate of his organization. Admittedly, he did so out of perceived necessity. (Read the book to get the full story!)

Today, though, when leaders say they are “committed” they usually mean they are willing to fund an effort, allow someone else to carry it out, get updates, and give encouragement. That might work for starting a subsidiary, but it doesn’t work for changing “how things get done.”

What we are talking about here is developing the competence and capability of the organization, step by step, individual by individual, as the primary daily work of leadership.

Capt Marquet describes his struggles, setbacks, how hard it was at times, and the long-term reward of his efforts – unprecedented promotion rates or personal successes among his former officers and crew in the 10 years following his time in command. His primary role was developing people. They happened to be the crew of a nuclear powered submarine.

Over the next few posts, I am going to explore the correlation between David Marquet’s leadership development model and Toyota Kata. Stay tuned.

In the meantime, read the book. It’s an easy read and worth your time.

Toyota Kata “A3 Problem Solving”

Over the years, I’ve been exposed a number of efforts to “implement A3 problem solving” in various companies. I worked for some of those companies, I’ve observed others.

The results are nearly always the same.

Here are a couple of examples. Let me know if any of these match up with experiences you have had.

Example 1: The company had put many people through “Practical Problem Solving” training and was (ironically) trying to measure how many problem solving efforts were underway.

I was watching a presentation by one of these problem solving teams to management. Their A3 was on a computer, projected onto the screen. They were reporting their “results.” Yet there were large discontinuities in their problem solving flow. The actions they were taking simply did not link back (through any kind of identifiable cause) to the problem they were solving.

The management team listened carefully, applauded their efforts, and moved on to the next topic of their meeting.

Example 2: A different company had a form to fill out called an “MBF” or “Management by Fact.” From the labels on the boxes, it was clearly intended to be structured problem solving. By the time I worked there, however, “MBF” had become a verb. It was a solo activity, filling out the form at the desk, and reporting on it in a staff meeting.

Example 3: Well-meaning former Toyota team members, now working for a different large company wanted to “train everyone in problem solving.” They put together a “class” that presented the purpose of each block on their A3 form with the expectation that people would adopt the process.

All of these efforts had something in common.

They didn’t work.

Over the last few days, I’ve been privileged to be included in an email exchange about the relationship between A3 and Mike Rother’s Toyota Kata. My small contribution was apparently enough to get my name onto the cover, but I want to give a real nod in the direction of a Jenny Snow-Boscolo for instigating inspiring a really good exchange.

The result is here. I think this presentation does a really good job of summing up the relationship between Toyota Kata and Toyota A3. Thanks to Mike Rother for taking the initiative and putting it all together (more below)

One of the difficulties with gaining insight into Toyota’s management processes is that they really aren’t codified. This shouldn’t be a surprise. Look at your own company, and ask how much of the culture – the reflexive way things are done and interactions are structured – is written down.

(In fact, if it is written down, I would contend it is likely your actual culture has little resemblance to what is written about it. Those things tend to be more about what they wish the culture was.)

Culture, any culture, is learned through daily interaction. This is all well and good in cases where people are immersed in it from the beginning.

But the rest of us aren’t operating in that problem solving culture. Rather, we are trying to create it. And as the former Toyota Team Members from Example 3 (above) learned, it isn’t a simple matter of showing people.

Rather than two different things, we are looking at a continuum here. At one end is the culture described on Slide 9. There isn’t any formal structure to it, the process for teaching it isn’t codified. It is learned the same way you learn the way to get the job done in any company. They just learn different things than you did.

But in another organization there is no immersion. If there is anyone who is steeped in The Way, they are few and far between.

In these cases, we want to start with something more overt. And that is the purpose of having a rote drill or kata. It isn’t something you implement. It is a structure, or scaffold, to learn the basic moves. Just as mastering the musical scales is only a prelude to learning to play the instrument, the kata is the foundational structure for learning to apply the underlying thinking patterns.

So… if you are working on kata, it is critical that you are reflecting on your thinking patterns as much (or more) than you are reflecting on your improvements. It might seem rote and even busywork at first. But it is there to build a foundation.

Navigating the Learning Hairball

Credit: A lot of stuff comes across my screen, sometimes more than once. I have seen this illustration several times, but don’t remember where it originally came from. If you created it, PLEASE comment so I can give appropriate credit.

Improvement is messy. Science is messy. Research and Development is messy. These are all cases where we want an outcome, are pretty sure what that outcome looks like, but there isn’t really a clear path to get there.

This illustration has illustrates two very different mindsets.

On the left is how many people believe the improvement / organizational development / learning process works. We set out a phased project plan to transform the organization. We carry out a set of pre-defined steps, and when they are completed, we are at the goal.

Sadly our education process is largely constructed on this model. Take the classes, pass the tests, the student is educated.

This thinking is appropriate when the outcome is something we have done before, like constructing a house. Even if this house is a bit different, the builders have rich experience in carrying out all of the constituent process steps. Further upstream, the designer carefully followed building and construction codes. In those cases, we are applying a rich body of experience (or the documented experiences of others) to reach the end goal.

These tasks can be scheduled and sequenced in a project plan. The steps are known, the result is known.

 

image

On the right is the hairball of learning and discovery.

We know where we are starting.

We know where we want to end up.

We are reasonably certain we can get from Point A to Point B. But we don’t know precisely which detailed steps or experiments will give us the results we need.

We don’t know for sure that the next result will be a forgone conclusion from the next action step.

Each step gives us more information about the next step.

In the world of continuous improvement, we live in an interesting paradox.

We often believe we are operating in the set-piece model on the left. We see a situation, we apply tools to duplicate a solution we have seen work in a similar situation before.

An interesting thing happens at this point. The Real World intervenes, and we discover that the situation was actually more like the right side. We thought we knew the right answers. We might have even been mostly right. But at the detail level, things don’t work quite as we predicted.

Now… if the system has been deliberately set up to flag those anomalies, and we are recording them and being curious to discover what we didn’t understand then we are in learning mode.

But all too often the experts who guided the original installation have moved on, leaving the people executing the process behind. The assumption was “It works, we can go to the next problem.”

The people in the process did what they were told, or guided, to do. We might have even asked for their input on the details. But that process rarely leaves them with additional skills they need to deal with anomalies in ways that make the process more robust.

So they do what they must to get things done. Mostly that means adding some inventory here, some additional checks or process steps there. Over time, the process erodes back to something close to its original state.

Why? Because we thought we knew everything… but were wrong. And didn’t notice.

This model applies to any effort to shift how an organization performs and interacts. We outrun our headlights and take on the Big Change because that company “over there” does it, and we just copy the end result.

What we missed was doing the work.

More about this later.

Creating an Empowered Team

EDIT: There is a follow-on post here: David Marquet: Turn the Ship Around

In the past couple of decades, we went through an “empower your people” fad. We saw work teams in world class companies that were largely self directing, surprisingly well aligned with the overall goals of the organization, and getting things done.

“Well,” we thought, “since empowered teams are obviously more effective, we’ll empower our teams.”

harry potter wandThey brandished their wand uttered some wizard’s chant, and bing! empowered their teams.

“What did you expect to happen?”

“We expected our newly empowered teams to self-organize, get the work done, plan all of their own vacations and breaks, and continuously improve their operations on their own.”

“What actually happened?”

“Work ground to a halt, people argued and squabbled, quality went to hell, and labor hours went up 20%”

“What did you learn?”

“That empowerment doesn’t work.”

Which is obviously not true, because there are plenty of examples where it does. Perhaps “Empowerment doesn’t work the way we went about it” might be a better answer. That at least opens the door to a bit more curiosity.

The last place I would expect an experiment in true empowerment would be onboard a U.S. Navy nuclear submarine.

Take a look at this video that Mike Rother sent around a couple of days ago, then come back.

A U.S. Navy submarine skipper isn’t generally inclined to swear off ever giving another order. It runs against everything he has been taught and trained to do since he was a Midshipman.

I’d like to cue in on a couple of things here and dissect what happened.

First is the general conditions. I think he could do this just a bit faster than normal because everyone involved was sealed inside a steel can for six months. Just a thought – groups in those conditions tend to have a lot of team cohesion.

But the mechanics are also critical. He didn’t just say “You are empowered.” Rather, this was a process of deliberate learning and practice.

What is key, and what most companies miss, are the crucial elements that Capt. Marquet points out must be built as the pillars of an empowered team.

GiveControl

Let’s put this in Lean Thinker’s terms.

As the Toyota Kata wave begins to sweep over everyone, there is a rush to transition managers into coaches.

“What obstacles do you think are now in the way of reaching the target?”

See the illustration above.

Competence and clarity.

I am going to start with the second one.

Clarity

Or… where the hell are we trying to go?

Capt. Marquet points out the critical element of commander’s intent. I learned this during my decade or so as a military officer (U.S. Army). When preparing operations orders, I had to clarify the overall commander’s intent. Why? So that when everything went to hell in a handcart, everyone knew what we were trying to get done even if the how to do it entirely broke down.

What that means in the lean thinking world is “What is the business imperative” or “What is the challenge we are trying to achieve?” If nobody knows “why,” then all they can know is “what” and that comes down to “implement the tools,” which, in turn, comes down to “because I said so” or “Because we need a 3 on the lean audit.”

Doesn’t work. Never has.

But I’m beating that topic to death right now, so I want to move the pillar on the left.

Competence

In my book, that means “The leader has a good idea how to do it.”

What does that mean in practical terms? In Capt. Marquet’s world, it means that, fundamentally, the crew knows how to operate a nuclear submarine. Additionally, it means they understand the ramifications of the actions they are taking on the overall system, and therefore, the contribution they are making to achieving the intent.

It doesn’t matter how clearly anyone understands what they are trying to get done if they have no idea how to do it.

In Lean Thinking world, competence means a few things.

  • The leader knows how to “do the math.” She understands the overall flow, the impact of her decisions on the system and the overall system.
  • The leader / coach has a good understanding of at least the fundamentals of flow production, and why we are striving to move in that direction.

While these things can be taught through skillful coaching, that implies that the coach has enough competence to do that teaching.

But if the coach doesn’t fundamentally grasp the True North, or doesn’t consistently bias every single conversation and decision in that direction, then Clarity is lost, and Competence is never built.

We end up with pokes and tweaks on the current condition, but no real breakthrough progress.

Day to day, this means you are on the shop floor interacting with supervisors and front line managers. You are asking the questions, and guiding their thinking until they grok that one-by-one flow @ takt is where they are striving to go.

In my Lean Director role in a previous company, I recall three distinct stages I went through with people calling me for “what to do” advice.

First, I gave them answers and explanations.

Then I transitioned to first asking them what they thought I would give as an answer.

Then they transitioned to “This is the situation, this is the target, this is what we propose, this is why we think it will work, what do you think?”

“Captain, I propose we submerge the boat.”

“What do you think I am thinking?”

“Um… you would want to know if it is safe?”

“How would you know it is safe?”

In other words…

What are you trying to achieve here? How will you know?

So here is a challenge.

If you are a line leader, especially a plant manager, take one week and utterly refuse to issue direction to anyone. Ask questions. Force them to learn the answers. Test their knowledge. Have them teach you so they must learn.

You will learn a lot about the competence of your team. You will learn a lot about your own clarity of intent. Try it on. No matter what, you will learn a lot.

Active Control

Imagine you are driving an automobile with a high-performance suspension. You are on a perfectly straight stretch of road, with smooth pavement. Get yourself up to, say, 65 miles per hour (100 km/h). Got it pointed down the middle of the road?

OK, close your eyes, let go of the steering wheel and wait. (Actually closing your eyes is optional.)

Can you predict what will happen, more likely sooner than later?

It doesn’t matter how “stable” your car is.

There are small, random things that are eventually going to cause your car to drift away from the centerline and off the road, into the ditch on one side, or over the cliff on the other. (Didn’t I mention those?)

I often see people set up a well performing process and treat it the same way – as though it will continue to work the same way forever, without any intervention.

But your process is going to encounter random chatter, and when it does, what typically happens?

In most cases, the team members can find a way to work around the issue, and likely continue to get things done, though they will have added a bit of friction, requiring a bit more effort, to do so. They will add a redundant check to make sure no mistake got made. They will add some inventory under the work bench, in case something runs out. They will carry the product over to the other machine because the one they are supposed to use isn’t working as it should be.

They will clean up the spilled coolant, catch the leaking oil.

They will head up-line to borrow a team member’s grease bucket.

They’ll tap out paint clogged or unthreaded holes, cut wires that are delivered too long to length, even drill new holes to mount the part that doesn’t fit.

In the office, they get one more signature, send an email to back-up the “unreliable” ERP messages, and make screen prints so they can enter the data into another system.

“Waste is often disguised as useful work.”

All of this easily goes unnoticed, and eventually (maybe) the process becomes cumbersome enough that someone decides to address it with an improvement activity. And the cycle starts again.

How do we stop the cycle?

The point of intervention is in the last paragraph… “All of this goes unnoticed.”

It isn’t a matter of standing and watching for problems. Sakichi Toyoda figured that out almost 100 years ago. It is about designing your process to detect anomalies in either execution (how it is done, how long it takes) or results immediately, signal, and trigger some kind of response.

Here are some fundamental questions to ask yourself:

Before the process even begins, does the team member have everything he needs to succeed? How does he know? I’m talking about parts, information, tools, air pressure, assistance… whatever you know is needed to get the job done.

If the team member doesn’t have everything needed exactly what do you want him to do?

Is the team member carrying out the process in a way that gets the desired result? How does she know? Is there a sequence of steps that you know will give her the result you want? What alerts her if one of them is skipped?

If the team member, for whatever reason, isn’t able to carry out those steps in sequence, exactly what do you want her to do? Go find a grease bucket? Or let you know?

How long do you want to allow your team member to try to fix something or make it work before letting you know there is a problem? Related to this – how far behind can you allow him to get before he can’t catch up, even with help?

Once the team member has completed the process, how does he know the result is what was expected? If the team member doesn’t have a way to positively verify a good outcome, who does detect the problem, when, where and how? It might be your customer!

An Active Control System

Even if you have all of those checks in place, however, you still need to answer a few more questions starting with “Once the team member detects a problem, what do you what exactly do you want them to do?”

I alluded a little to this above, but let’s go a bit deeper.andon-pull

On a production line, a typical way for a team member to signal a problem is with some kind of andon. This might, for example, take the form of a rope along the line that the team member can pull in order to trigger a signal of some kind.

But that is the easy part. Lots of factories have copied the mechanics of Toyota’s andon only to see them fall into disuse following a period of cynicism.

The hard part is what is supposed to happen next?

Now we are back to the original questions because the andon is nothing more than a trigger for another process.

Who is the designated first responder? (Remember, if it is everybody’s problem, it is nobody’s problem.) Does that person know who he is?

What is the standard for the response? What is the first responder supposed to do, and how long does she have to do it?

When we had takt times on the order of dozens of minutes, our standard for the first response making face-to-face contact with the team member who signaled was 30 seconds.

How much intervention can the first responder make before being required to escalate the problem to the next level?

As a minimum

As a minimum, the first responder’s primary goal is to restore the normal pattern of work. This might be as simple as pitching in and helping because something minor tripped up the team member’s timing.

This is active control – a system or process that detects something going outside the established parameters, and applying an adjustment to get it back. Active control requires a process to detect abnormalities, a trigger, and a response that restores things. It is no different than maintaining thickness in a rolling operation – the machine measures the output, and adjusts the pressure accordingly – or an autopilot that keeps an airplane on course.

Without some kind of active control system, your process will erode over time as the team members do the only things they can do in an effort to keep things moving: They can overproduce and build inventory to compensate, they can add extra process steps, they can add just about any of the things we call “waste.”

The only question is what do you want them to do?

The Struggle

In The Leader’s Journey, I highlighted the struggle with escalating challenges as a core driver of growth in both our fictional heroes and real-life developing leaders.

This week I was essentially doing 2nd level coaching with a client I have been working with for quite a while. One of the things we did was have a brief session where we reviewed and reflected the ideal state of a coaching / problem solving culture (thanks in large part to Gerd Aulinger and Mike Rother). We reviewed the principles of what a coach and the coaching chain is striving to achieve, and the mechanics of doing it.

Combining that review with the shop-floor 2nd level coaching, a couple of my participants commented on how much better they “got” what they were trying to do. They started to move from rote to the higher-level understanding.

I am still digesting why this week had this kind of breakthrough when we have been working on the same key things for months. Nothing we went over was new information. What was different this time around?

My thought right now is that they have been in the struggle trying to understand this stuff, and finally reached the point where the additional theory snapped things into place. I told them “if you hadn’t been struggling with this, you wouldn’t have had the insights you got this week.”

I really think that is the case. We can give people all of the answers. But I am realizing if they haven’t, first, been struggling to find those answers on their own – if they haven’t been trying hard to figure it out – then the additional information would have far less (or little) impact. It is only after they have challenged themselves that the externally supplied insights have any meaning or context.

At least that is where I am right now. Time for a couple of additional experiments.

What Mode Are You In?

The main purpose of an andon is to signal that some part of the system is no longer in normal operating mode. The immediate response should be to quickly assess the situation, and recover the process to the normal mode.

Many organizations, however, do not make that mental shift. They don’t have a clear sense of whether they are in the normal operating pattern, or in recovery mode.

Without that sense of mode, “recovery” can quickly become the norm, and a culture of working around problems develops. Sometimes we call this a “firefighting culture,” but I find that term regrettable, as it reflects poorly on actual firefighters.

In the andon driven environment, the andon is either on or off. That is, things are either operating as they should be (no andon) or they are not (andon is triggered).

All of this presumes, of course, that you have some idea what your normal operating pattern should be. Go and walk your shop floor or work area. What can you see happening?

Is what you see what you want to be happening? How do you know? What do you compare it against?

Can the people working there tell if they, and their process, are in the normal operating pattern, or in some other mode?

If they are recovering, do they know they are recovering? Are they striving to get things back to the normal operating mode; or are they striving to simply get the job done in spite of the immediate problem? Big, big difference here. This is what makes or breaks your continuous improvement effort.

Once the normal operating mode is restored (assuming you had one), are at least some of these incidents investigated down to root cause, with countermeasures tested by appropriate PDCA cycles and experiments?

What mode are you in right now?

How can you tell?

The Leader’s Journey

Earlier this year, Sir Ken Robinson gave a great TED talk about the state of education in the USA. While his talk was about K12, nearly everything he says applies to how we grow and develop leaders.

Or stifle their growth.

He makes it clear that no teaching is taking place unless learning is taking place.

And he points out that if we create an environment that encourages curiosity, then we get creativity and learning in return.

But many of our organizations and institutions almost seem to be designed, instead, to discourage curiosity. If being wrong or incorrect has negative consequences, then the safest course to take is one which makes no commitments and questions nothing.

Robinson finally points out that the ability to grow and learn is in all of us. It is much more a matter of the right conditions than it is innate talent or skill.

I would like to suggest that creating those conditions, and that process of growth, is deeply embedded in nearly all of our cultures and in our very humanity.

This growth is what the management consulting business calls “change.” Change is a hot topic. There are bookshelves, file drawers and web servers chock full of advice on how to “change.”

But what are we really talking about? Though we discuss “organizational change,” I think the process of “change” is deeply personal to each individual. It is a process, not so much of adopting new behaviors, but of personal growth.

And as individuals grow, connections between them strengthen, and the organization as a whole performs. But it’s people that change. And that change, more often than not, comes down to growth and confidence in the face of adversity.

So how, exactly, do people “change?”

Let me tell you about Karen.

She is a typical supervisor in a typical small manufacturing company. The company could be anywhere.

Karen is responsible for the shipping department. She oversees the work of about half a dozen people who process customer orders, pick the items, package them, label them, pack them and ship them.

As straight forward as this sounds, the real world throws a lot of chaos at Karen every day. They don’t know how many orders they are going to get, yet Karen must maintain a reasonable level of productivity.

Some orders are simple, others are complex with multiple packages being consolidated into a single shipment.

Sometimes the items aren’t on the shelf even when the computer insists they are.

A typical day for shipping was a continuous push to get the orders picked as soon as possible, then a push to get the orders packed, then there was the Big Push at the end of the day to try to force everything through the shipping process and ready for UPS.

Karen was coming in at 2 or 3 am to sort through paperwork and try to organize things. During the day she was working to manage the Big Pushes, move people to where the work was. And at the end of her 13 hour day she went home exhausted. And the next day she got to do it all again.

Meanwhile, in the background, a storm was brewing. We had identified an opportunity with great potential for productivity in manufacturing and shipping. But for Karen, that “opportunity” meant her team had to take on higher volumes of work with no more predictability than what they were already struggling to get out the door.

Let’s just say that Karen was skeptical. She was convinced there wasn’t any way, short of increasing her staff, that this could be done.

Karen was a good sport though, and grew into the challenge of learning how to break down and analyze the work steps, and get on-by-one flow into place. It was a lot of work as she tried some things that didn’t work in order to learn more about the things that did. Throughout this process, she was getting support, encouragement, advice and coaching from a couple of key, experienced people.

But it was Karen and her team, not her coaches, who were solving the problems because it was Karen’s team who had to live with the solutions.

A few weeks later I was back, and we were taking another team from another department through the same process. To give them a visible example of what to strive for, we went to shipping to let Karen show them the changes they had made, and were continuing to make, and explain the new work flows.

It turned out that one of the people getting that little tour had done Karen’s job a few years ago. Her first question was “Is the computer down?”

“No,” said Karen.

“Are you having a really slow day then?”

“No, in fact this is a pretty busy day,” was the reply.

“But…” with an incredulous look “… it’s calm.”

And yes, it was calm.

In addition to the process changes, Karen was leading differently.

Instead of being “Hurricane Karen” and disrupting the flow of work with constant intervention, she was starting to trust the flow and visual controls to tell her where she needed to pay attention.

When she was surprised by something, she was asking “What would have let us spot that issue sooner?”

She was beginning to manage problems and exceptions with an eye toward preventing them.

Her new skills were still rough and needed practice, but she was working hard to apply them. She was still getting a lot of coaching, but it was mostly to help her stay on track and not get distracted from the path by the urgent.

There was still a looming challenge, however.

While the new process had dramatically improved quality and productivity, the “one order at a time” rule that made it all work had the side effect that the pickers were doing a lot more walking up and down the aisles.

Karen was feeling a lot of pressure to go back to picking batches of orders. She challenged her coaches, and they challenged her to look at why the walking was necessary in the first place.

They found fast moving items in locations at the very back of the store;

And long one-way aisles with no cut-throughs and no room to turn around a cart;

The locations were poorly marked, increasing the time to search for something.

Pulling and picking one order at a time wasn’t causing more walking, it had highlighted the poor organization of the storage area.

Holding the line here took a lot of courage. Karen had to step up her leadership and gain the faith of her people.

She also had to learn to work with other parts of the organization to:

  • Get slow moving and obsolete items off the shelves to free up space.
  • Get a more rational location system into place.
  • Take advantage of the increased shelf space to open things up; put breaks and cross-over points in the aisles; and create wider aisles where carts could pass one another.

This was new territory, technically and politically. As a side-effect, the company had the insight that working on their changeover times in injection molding would have a direct effect on how much walking parts pickers in shipping had to do. I’ll let you figure out why those things are tightly related.

Some months later I was back again, and of course went to see Karen.

Now she was telling me about her initiative to take on even more volume by creating capacity from wasted time.

Karen had observed that they spent a lot of time counting out little parts into bags. Working with her team, they had developed a simple, inexpensive, part counting jig that mounts on the cart. They worked this out through a series of trials and experiments, solving one problem at a time, cut the counting time by around two thirds.

2013-02-07_14-47-10_376See that red spoon? Some of their parts are silver, others are white. And there are other colors as well. Their experiments had shown that candy red gave the best contrast between the parts and the spoon used to scoop them from the counting tray into the bag (even the red ones), thus reducing the opportunity to mis-count.

Who has time to think through this level of detail?

Karen and her team do now, because getting the daily work done is a matter of routine rather than a daily battle. She has time because, through her leadership, they have created that time. She took this last initiative on her own. She took what she had learned, and is now applying it every day.

When we talk about “change” this is what it looks like. It is people that change, and when they do, the organization changes with them.

Most of us have stories like this – of someone we know who was initially reluctant or skeptical;

Who overcame those initial doubts and committed themselves to a course of action into the unknown;

Who worked through a series of challenges, overcame them, and emerged change in some small, or large, way.

We find these stories compelling… but why?

This is the story of

The Karate Kid

Harry Potter

Dr Grant in Jurassic Park

Huckleberry Finn

It is the story of Beowulf, of Dorothy Gale, and Gilgamesh, of Alex Rogo in The Goal, Tom Hank’s character in Castaway and the real-life story of Apollo 13.

Snow White, Cinderella, Sarah Conner, Luke Skywalker, and on a grand arc, even the story of Darth Vader.

The story is told and set on sailing ships, star ships, in little cafes in Morocco, and across countless urban legends.

It is a narrative that is embedded in the psyche of every human culture from the dawn of storytelling.

And it is the continuing story of Karen.

Some of you may have heard of Joseph Campbell. His work became well known after a series of interviews with Bill Moyers in 1988, broadcast a year after Campbell’s death. The most famous of Campbell’s work is The Hero with a Thousand Faces. Campbell found common elements in nearly all mythology and stories across all human culture, throughout human history.

We tell these same stories, with different twists and forms, over and over. But they all have a similar underlying structure.

This isn’t about a formula for story creation, rather, our compelling stories follow the path taken by those we admire in real life. The stories and myths are concentrated for effect, but the transformation is the same. Although there are a lot of variations, there are some patterns of common elements.

What makes them compelling is growth through perseverance.

The Dragons, Orcs, Wicked Witches and Grendel all represent our inner fears and doubts.

What makes the “hero” – and our emerging leaders – is the willingness to set aside those fears and take on the challenges.

That, in turn, produces growth – what we call “change.”

It is individual people that change, and in the process of changing, they often follow their own “Hero’s Journey.”

The Mundane Life

The stories start with the protagonist leading an ordinary, often mundane life. He or she may be satisfied with that life, or may be yearning for something more.

Dorothy is on the farm in Kansas dealing with the demands of her aunt, and her little dog getting into trouble, dreaming of somewhere over the rainbow.

Sarah Connor is a waitress in a diner, and Bilbo is enjoying his days sitting outside and contemplating the scenery.

Nothing about Karen’s work life was mundane, every day was a new battle. But the battles were fought over and over. Victory was survival until tomorrow morning.

The Call

Early in the story, the hero often receives “the call” to depart the ordinary life into something compelling but unknown.

Sometimes “the call” is a violent event, like a tornado carrying the house to Oz. Other times it is an opportunity to “take the red pill.” It could come in the form of a change in the dynamics such as the arrival of Buzz Lightyear in the toy box.

Karen’s “call” was being asked to participate in a kaizen event to examine the very work that she managed every day.

Refusal of the Call

Often the hero initially refuses the call. Karen was very skeptical.

They often do not feel up to the challenge being issued, or feel they cannot leave their current responsibilities.

Nevertheless, in our stories, the call is eventually answered, and sometimes events compel the protagonist to act.

This is a point in the development of a leader when we must have empathy.

We have to realize that the known, no matter how ugly it may be, is at least predictable and safe.

Karen knew she had to come in at 4 am every day, and she knew she would be battling to keep things on track.

She knew she would be there late to make sure everything got done.

And she knew that the process would utterly fail if she did not do these things.

It was completely reasonable for her to be skeptical that it would be possible to change this dynamic.

Sadly, too many of us are quick to frame these reasonable fears as “resistance to change” and make judgments about the protagonists in the story unfolding in front of us.

But our reluctant heros-to-be are holding the best interests of the organization in their hearts. What we call “resistance,” most of the time, is actually fear of letting people down. We need to empathize with this fear because it is in all of us. In other conditions, that same fear also motivates great heroism and sacrifice.

The Mentor Figure

In a real-world organization we are all too willing to abandon people into stressful situations and expect them to step-up. In my own studies of world-class management systems, though, I have found a common theme:

The primary responsibility of true leaders is to coach and develop people.

In The Hobbit and The Lord of the Rings trilogy, Gandolf represents the mentor or spiritual guide. In The Goal this role is played by Jonah. We see Tinkerbell with pixie dust, retired Jedi Knights, and fairy godmothers.

The mentor cannot actually be the hero, but is highly influential in the hero’s development by providing guidance and emotional support.

In our story, Karen’s “Gandolf” was Brian, the Continuous Improvement Manager. This role, however, is temporary for Brian. Ultimately this role falls to Karen’s boss, Carlene. But Carlene is on her own journey as this company was still in transition.

Brian took on the role of giving Karen the training and guidance to help her along her journey.

This is very different than sitting her down in a class and deluging her with PowerPoint slides about general principles.

Though only Karen can lead her group, Brian was there to make sure she succeeded.

Crossing the Threshold

In the Hero’s Journey there is usually a moment when the protagonist steps from the ordinary world into the world of adventure and learning.

Campbell calls this “crossing the threshold.

After the tornado drops her house into Oz, Dorothy opens the door and sees and world of Technicolor. “Oh Toto, this isn’t anything like Kansas.”

Luke Skywalker goes to the bar to meet Han Solo.

John Dunbar moves to the Sioux village.

Karen entered the kaizen event on Monday morning.

The Journey of Adventure

Of course, “one does not simply walk into Mordor.” Actually you do. But there are obstacles to overcome.

The new world is different, and our hero must learn its rules, find new friends and allies, and overcome new challenges that usually increase in drama and complexity.

These events and experiences shape the growth of the character as he transforms.

As leaders develop, their styles and approaches change. They must. When leaders change their style and role – like Karen – they still face challenges from the people around them.

Karen was developing and testing new skills. She had never been taught how to carefully study how the work was done. We taught her.

She had not considered how smooth, steady work was faster than pushing everything. She learned by trying and experimenting. We taught her these things by teaching problem solving in the context of what she was trying to get done.

The emerging leader must be willing to learn, which means being willing to try something she doesn’t know how to do, and fail a few times.

The Mentor’s job is to shape the path forward and provide support, technical and emotional, throughout this process.

During this part of the journey, the hero usually acquires something – what Campbell calls “the elixir” but it may be symbolic and take the form of new knowledge or skill, or a great insight.

Karen’s “elixir” was developing faith that it was possible to calm down the chaos of shipping, to see problems sooner, and deal with them before they turned into disruptions.

The Final Confrontation

In our mythology, there is often a Big Confrontation toward the middle or end of the story, a symbolic death and rebirth. The protagonist must draw upon the strength that was gained up to this point, and emerges with new confidence, a changed person.

Dorothy had the courage to stand up for her friends and confront the Wicked Witch who, back in Kansas, had been trying to take her dog away.

Even though things were much better, Karen was confronted about the additional walking, and had her meddle as a leader tested. Where she might have argued in the past that this wasn’t working, per perspective was now “How do we move this forward?”

The Journey Home

Now the hero must return. Often there is yet one more confrontation and a final chase scene.

The hero re-enters the “old” world, but profoundly changed. Sometimes the world itself has changed, other times the protagonist’s response to that world has changed. Either way, things will never be the same.

Sarah Connor was no longer a waitress in a diner. She was tough, alert, and protecting the future savior of humanity.

Karen was learning to delegate the things she had previously done personally, and allow the process to handle them. Her management style has shifted from “Who is doing what?” to “Is the process working as it needs to?”

Oh – and maybe she doesn’t see it, but I do. Her mannerisms have changed. She is far more articulate and confident.

Why did I take your time to map this analogy?

When I read Jeff Liker’s book that describes Toyota’s process of leader development, what really struck me was the principle of self development combined with stepping up to the challenge.

A prospective leader is offered a challenge to take on a project that is likely outside of his or her current experience and knowledge base. While there is, without a doubt, an urgent business imperative, it is also a process of developing leaders.

The challenge is probably scary. The prospective leader has an opportunity to refuse the call and remain in her current job for the remainder of her career. There are certainly people who are very happy working on the assembly line until they retire. There is no prejudice here. How you reach fulfillment in your life and career is a decision as unique as your DNA.

But if the “challenge” is simply “make the numbers or we will find someone who will” the story can fall apart. Yes, there are truly exceptional people who can dig out of those challenges on their own. But they are rare.

We have to realize that, even in our adult post K12 world, our organizations must be institutions of learning.

And the way people learn is through experiences. Not just any experiences, but experiences that illicit specific emotions. It is the act of struggling with something we almost get that resets the neural patterns in our brains.

Today, we know how to teach emerging leaders to become critical process thinkers.

We do it by teaching routines that, once mastered, become thinking patterns. We guide them through that struggle in a kind, supportive, challenging way.

You may remember “Wax on, Wax off” from the classic motion picture Karate Kid (or perhaps you recall “Hang up coat” from the recent remake). Those basic motions were used to build strength and motions that could be carried out without thinking. In Japanese martial arts, they are called “kata.”

Thanks to research by Mike Rother, published in his book “Toyota Kata,” we are actively experimenting with a “kata” for learning foundational problem solving and leadership skills.

But this learning does not occur without motivation and perseverance. If we want to grow leaders and innovators, we have to understand that each of them must go through their own Hero’s Journey and emerge in their own way.

The path is not known beforehand.

What we can do, though, is recognize the pattern of human growth, support it, and create the best possible environment for people to find their path.

___________

Update: August 20, 2015 – two years later. I saw Karen again today. She is now overseeing the assembly department, which is much more complex. Her successor in shipping was telling me about her challenge to improve counting accuracy for larger orders (~100 small parts). The journey continues.

Another update: Karen is now overseeing injection molding, the most critical value stream in the company. Her first step there was to make sure the work schedules were realistic, visible to all, and to begin understanding what obstacles were coming up to prevent attainment. Then she started working on them.