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.

Embracing instability

Kaizen is largely a drive toward stability – that is a more consistent operation, producing a more consistent result. The key is the definition of “consistent.”

Overproduction is a way to achieve the illusion of consistency in the face of inherently unstable operations. Your machines are unreliable? Run faster when you can run. Inconsistent quality? Make more stuff so you have enough good ones.

And you know what? If my machines are unreliable, I do run faster. I put in buffers of time and material. I have to, because at the end of the day, I need to satisfy the customer.

The difference is in what I am trying to do, and how I define “stable.”

If I were to define “stable” as “I don’t have to pay attention to this” then my natural reaction will be to bury the problem by building in accommodations – things I “have to do” because “the process isn’t stable.”

Once there are sufficient accommodations in place, I, as a manager, could shift my attention elsewhere.* We all know the downside of this – those problems accumulate, and eventually the system fails completely. But our brains are programmed to assign cause to recent events, even if they were simply the tipping point.

The reflex reaction, then, is to look at something that just happened, assume that was the problem (since everything was “fine” before), and find a short term fix to make it go away.

I see this quite a bit. That is why I am now quite… inquisitive about the ongoing process improvement efforts if I hear a target condition as some level of performance, and “the process is stable” as the current condition.

No problem is a big problem.


*I may very well put in a temporary countermeasure so I don’t have to deal with all of the obstacles and problems at once. It looks the same if you are touring the shop floor. The difference is intent.

Kaizen vs. Kaizen “Events”

I got an interesting email from a friend a while ago, and am finally finishing up this post about it. Some months ago, he joined a new company and wrote about his impressions of some of the legacy he was walking into:

[before my arrival, the company] used Xxxxxx consultants to get their Lean effort up and running. 

They were given training modules that are 30-40 slides long and unbearable to sit through. 

They were taught a very rigid approach to kaizen that focuses more on strict standards than helping to improve performance. 

As a result there are deep divides between some of the groups here and the Lean team.  It’s unbelievably frustrating to see how much money was spent learning an approach to Lean that is outdated and ineffective.

Actually, it was worse than ineffective, it was detrimental in a lot of ways.  There are numerous areas we have to dig ourselves out of a hole that was created by events that absorbed substantial resources for zero long term gain.

He goes on to ask for a discussion on The Lean Thinker…

[…] about the event and tools based approach versus the daily problem solving approach.

And goes on to observe:

There is still a deep divide in the Lean world as to which is the best method.  It’s seems to me that there are more people on the event and tools side of the fence than there are on the daily problem solving side of the fence.

I included these quotes because this is a real perception from the real world. My friend recognizes the need to adopt daily improvements driven by line leaders.

What he sees, though, is that these kaizen events didn’t (in his view) transfer those skills, or that behavior, to the organization.

There is nothing unusual about the process described above. I was taught pretty much the same thing: A “kaizen event” is about a specialist workshop leader planning and conducting the event “to the standard.”

Who are you developing?

This approach does develop a skill in the organization.

A relatively small group of people (usually the promotion office staff) get pretty good at planning and running kaizen events following whatever standard is in place.

They get good at it because they are the ones who plan and run those events, over and over. In other words, they practice.

That, of course, begs the question: Who are you developing?

I’ve seen (and been in) a number of companies who strive to have “every team member participate in at least one kaizen event a year.” In a plant with 250 team members, at 8-12 of them participating in a typical kaizen event, that works out to something like 25 kaizen events a year, or a bit more than two a month. A typical promotion office staff in a plant this size might be able to keep up with that rate, but I have seen more struggle to do so than succeed.

So with this tempo of kaizen events, each team member gets to participate in an improvement activity roughly once a year.

Granted, a lot can get done over the course of that week. But the other 49 weeks are business-as-usual, so business-as-usual is what they are learning.

Put another way, if you want to get good at skiing, it is going to take more than one week on the slopes every winter.

More Important: What are you striving for?

This is really the same question I asked above, but in the context of the purpose of your kaizen events.

What was that consultancy striving to do with their client?

What was the client striving for?

My guess is both were pushing hard for rapid measurable results – an immediate and visible return on the investment.

But if you are striving to develop leaders, then the kaizen event takes on a completely different tone. (Note that when I say “leaders” I don’t limit myself to people in formal leadership position. I mean anyone who is willing and able to step up to a challenge, and enlist the help of others to meet it.)

There is also a very different expectation for what happens after a kaizen event. No longer do we have lists of actions to complete. Rather, we have the current obstacle we are working on, and the next experiment that is going to be conducted on Monday.

The key is that a kaizen event has to kick-start a change in the daily routine that goes above and beyond changing the work. I’ll go so far as to say that changing the work is secondary. If you can kick start getting improvement as part of the daily work, then the work itself will improve quickly enough.

Your measure of success, then, is not the results you get during the kaizen week. It is whether or not you can sustain the rhythm of improvement thereafter.

Just some things to think about.

PDCA, A3 and Practical Problem Solving

Over the years, I have been party to at least three corporate-level efforts to bring “A3” or “Practical Problem Solving” into their toolbox. Sometimes it has other names, such as “Management by Fact” or such, but the approaches are all similar.

Typically these efforts, if they catch on at all, become exercises in filling out a form.

Actually, that shouldn’t be a surprise, because they are often taught that way – as process of filling in boxes in sequence, with a “module” for teaching each step.

Worse, it is often taught as an intellectual exercise, and once you are done with the three day class, you’ve been “taught.”

The various classes mention PDCA as being a crucial part of this process, but nobody really practices it.

People are sometimes taught that this process should be coached, but the “coaching” they get is typically organized as management reviews via PowerPoint.

The “problem solving team” shows their analysis and their “implementation plan” that is a list of tasks, and a timeline to get them done. The meetings become status reviews.

Sometimes the “coaches” offer suggestions and speculation about the problem, symptoms, or actions that might be taken. They rarely (if ever) get into the quality of the PDCA thinking.

This is one of the challenges we have in the west (and especially in the USA) where our culture is more one of “go it alone then get approval” rather than true teamwork with the boss. This often turns the “A3” into an exercise of getting approval for a proposal rather than a learning process.

Worse, it does nothing to teach the problem solvers to be better problem solvers.

Note that sometimes an A3 is used for a proposal, but the process of creating it is still coached, and part of the process is the consensus-building that happens before there is any meeting. But here in the west, we still seem to like to spring these things on a leadership team without a lot of that background work ahead of time.

Mike Rother and the “Toyota Kata” community have been discussing this gap lately, and working to close it.

The latest iteration is this SlideShare that Rother sent around today:

He clearly points out what people have been missing: The “A3” is really just another method to document the “improvement kata.”

The “Implementation” box, rather than representing an action item lists, is where the problem solver captures her PDCA cycles, what is being tried, what is being learned, as she drives toward the target condition.

The other boxes are capturing her understanding of the current condition, the target condition, and the impact of various problems and obstacles in the way of closing the gap.

One thing that makes this extraordinarily difficult: We are talking about more than the mechanics of problem solving here. We are talking about shifting the default, habitual structure of the interaction between people. That is culture, which is notoriously hard to change. Not impossible, but unless people are up front that they are actually trying to change at this level, there are a lot of obstacles in the way. This can’t be delegated.

Results

Past Due Hours

This area was picked for the initial focus because they were way, way behind, and it was getting worse.

The initial work was done in mid-April. The target was consistent output at takt time.

As the team looked at the process, and identified the sources of disruption and variation, “changeovers” surfaced pretty quickly as a main issue.

“Which obstacle are you addressing now?” was the changeover times on the output process, so the target condition for the area’s team was to get the disruption to output for a change over down to a single takt time vs. the highly variable (up to 10 takt times or more) disruptions they were seeing.

One big mindset change was the concept of takt time. There was a lot of perceived variation in the run times of these parts. But upon study, the team realized the variation was a lot less than they thought. Yes, it is there, but over any given couple of hours, it all evens out most of the time.

As the team studied their changeovers, one of them had an insight that “We can do a lot of these things before we shut the machine down.” And in that moment, the team invented the SMED methodology of dividing “internal” and “external” changeover tasks.

hours-past-due-sm

Once that objective was grasped, they went to town, and saw lots of opportunities for getting most of the setup done while the last part was still running.

Their lot sizes were already quite small, the core issue here was the disruption of output caused by the increased tempo of changeovers. So that time was put back into capacity, resulting in the results you see above.

They continue to work on their changeover times, have steadily reduced the WIP between process stages, and (as you can see) keep outrunning their goals for “past due hours.”

But the really important bit here is that this was largely the team leaders, the supervisor, and the area manager. Yes, there was technical advice and some direction giving by the VP and the Continuous Improvement manager, but the heavy lifting was done by the people who do the work every day.

Consistent Output

This is from another company, in a completely different industry. Their issue, too, was that they were always behind. In this industry, the idea of a takt time is pretty alien. Even the idea of striving for a fixed level of output every day is pretty alien.

The team’s initial focus was maintenance time. They perceived that equipment reliability was causing them to fall behind in production, and so were shipping product to a sister plant every week to fill in the gaps.

The first question posed to them was “How much time is needed for production?”

In other words, they needed to figure out how much production time was “enough,” so they could then assess how much time maintenance could have. That would establish their target.

But in answering that question, they developed a takt time, then measured output cycles vs. that takt. What they saw was lots of inconsistency in the way the work was being done.

If they could hold to something close to their demonstrated lowest-repeatable cycle times, they could then know when they were “done” for a given shift, or day, and actually plan on maintenance time rather than seeing it as a disruption to production.

The focus shifted to the work cycles.

What is cool about this team is that the team leader / “learner” (in Toyota Kata terms) was the maintenance manager.

He gained a real shift in perspective. “Production” were no longer the people who wouldn’t let him maintain the machine, they were his customers, to whom maintenance needs to deliver a specified, targeted, level of availability as first priority.

The teamwork developed about the end of Day 2 of this intense learning week, and they have been going after “sources of variation” ever since.

Here is the result in terms of “daily output:”

output

As you can see, not only is the moving average increasing, but the range is tightening up as they continue to work on sources of variation.

The big downward spike on the right is two days of unplanned downtime. In retrospect, they learned two things from that.

  1. After foundering a bit, they applied the same PDCA discipline to their troubleshooting, and got to the issue pretty quickly. As a sub-bullet here, “What changed?” was a core question, and it turned out someone had known “what had changed” but hadn’t been consulted early on. Lesson learned – go to the actual place, talk to EVERYONE who is involved rather than relying on assumptions.
  2. Though they sent product out for processing, they realized they could have waited out the problem and caught up very quickly (with no customer impact) had they had more faith in their new process.

All pretty cool stuff.

These things are why this work is fun.

Policy Deployment and the Coaching Chain

Gosh, I guess it is a couple of weeks ago now (I’ve been up to my eyeballs in work), Gerd Aulinger posted this presentation up on the Lean Enterprise Institute’s “Kata” page:

I’m obviously interested in your comments as I had some amount of input into the final product.

For that, I would ask that you actually download the SlideShare, print it out, parse it, discuss it with others, and really pick apart what it means.

There is a lot in here, more than you find in a typical LEI workbook.

But I’d also like to discuss what I think are important points made here.

Continuous Improvement is a Line Leader Job

Though it isn’t stated explicitly, the very structure of this example only shows the roles of line leaders. You don’t see anything about kaizen events or rapid improvement workshops led by staff specialists here. Each leader is directly responsible for getting the process to the next required level of performance.

Improvement isn’t “What Can We Do?” It is “What Must We Do?”

There is a business imperative underlying this entire effort. They didn’t just make a value stream map and ask “Hmmm… how much better could we make this by taking out some waste?” Nope, this is driven by a need to get a level of performance that, today, they cannot achieve.

As a sidebar, please note that the “kaizen bursts” are on the FUTURE state map (slide 28) … they represent the OBSTACLES in the way of getting there, not “opportunities” on the current state map.

If you look at the target condition for the changeover, it is 14 minutes. There is nothing sacrosanct about a 10 minute changeover, that is just from the name of a book. They need to get changeovers to 14 minutes to get the process performance they want. It’s math.

Added, thanks to a comment from Kris:

“Catchball” is More About “How” than “What”

You will notice there is some back and forth – what is commonly called “catchball” in the dialog between the various levels of coaching. But they are not discussing the overall business imperative. They are discussing the obstacles, targets, and approach that will be taken to get there.

This is an important point because, in the early days, “catchball” was taught by many consultants as a negotiation of the objectives.

But Nancy’s objective isn’t negotiable. What might be negotiable is how much of her lead time objective gets carried by gear machining vs. the unseen conversation with assembly, a cap-and-trade of sorts, but in the end, her group is on the hook to hit her target.

The Entire Chain is Fractal

When Nancy asks Steve “Which obstacle are you addressing now?” he responds with the long changeover… while that changeover is the target condition between Steve and Roger.

Steve is working with Roger to break that obstacle, to hit the 14 minute changeover, thus this is what he tells Nancy he is working on now. The presentation doesn’t go into the further details of their discussion (heck, it is already up to 80 slides…), but I’d venture to say that conversation is going to be as much about how well Roger is doing figuring it out and his learning conditions as it is the process itself. Why? If Steve did it himself, Roger wouldn’t learn anything.

Continuous improvement is about continuously improving people.

At the next level down, Roger is addressing obstacles one by one.

Roger’s target condition of a 14 minute changeover breaks down to obstacles that he thinks are in the way of getting there. Each of them has an unknown solution, and so must be broken down systematically. The terms change, but the process is just getting finer grained. We finally get down to individual experiments to test an idea and learn more about the process.

Improvement is a Team Sport

There are a lot of sports analogies, heck, “kata” itself is a sports analogy of sorts. But the key is that this isn’t just giving someone an objective and having them report progress. Though the “coaching kata” seems ritualized, there is a lot of nuance.

As I mentioned earlier, a lot of novice coaches, especially those whose normal work patterns are to delegate the details, fall into the trap of thinking they can just recite the coaching questions and they are coaching. It actually takes a lot of practice reading how far you can push your learner today, what he is struggling with, knowing when to give direction, vs. give a hint, vs. let her try something that the coach is pretty sure won’t work but will be a learning opportunity.

That means the coach has to be able to see things the learner or improver might miss. Sometimes those things can only be seen from an outside perspective. That is why expert Olympic-class athletes have coaches. There are some details that cannot be seen from inside.

Being with people in a supportive but challenging way so they can learn and develop is one of the key elements of respect for people.

 

 

Mike Rother Overview of Toyota Kata

This is a 5 minute edit of the presentation Mike Rother made at the UK Lean summit.

It is a succinct summary of interaction between a coach (leader) and learner (someone working on improving a process).

My thoughts are below the video…

OK – here are some things I have learned with these methods “in the wild.”

Most organizations I have been working with can’t take on 1-3 year challenges and stay the course for that duration. The horizons are too far for them to see what is possible within that kind of time frame and stay the course.

I have been trying 3-4 month time horizons for initial challenges in organizations where everyone is learning the basics at all levels. That gives them an opportunity to practice with a horizon that is less likely to be derailed by a sudden change in direction during that time. Eventually, as they develop capability, they can extend the time horizon and morph these practice challenges into something more formal, linked to the business plan.

Middle managers like to leap onto the coaching questions much too early – before they are capable of actually coaching. The coaching questions are seductive because they are written down and structured.

The PDCA process is much more nuanced, but it must be mastered before attempting to coach. Why? Because the coaching process is application of PDCA toward the learner’s development.

While it is OK to round-robin coaching and actual process improvement, everyone has to work together to reflect and learn.

In addition, those middle managers tend to try to leap into coaching before they have an internally set non-negotiable sense of “True North” – driving toward better and better flow.

When a middle manager is taking on the role of the “learner” there is a great temptation for him to delegate tasks to others, and get reports. This is status quo, and does nothing at all to develop capability.

Like everything else we do in the West, or at least in the USA, we try to get there fast by skipping the basics.

Make no mistake – you don’t “implement Toyota Kata.”

You use it as a structure to build foundational capability and new thinking patterns.

Those patterns are only developed through practice, and deliberate reflection on the management process itself.

I have also seen an organization that is “getting it” pretty quickly. The difference is that they are all overtly in “we are just learning this” mode, and willing to make mistakes and learn from them vs. trying to appear to be competent from the get-go.

Mike Rother has other videos on YouTube as 734Mike.

Constraints Push Innovation

This Ted Talk by Amos Winter is about a fantastic project to develop an inexpensive, rugged, rough-terrain wheelchair for people in countries with much less infrastructure than we take for granted in the U.S. and Europe.

Though they didn’t follow the traditional “3P” approach, their project did reveal a few key elements. More below the video.

What Winter talks about as constraints:

  • Cost < $200
  • Parts readily available
  • Repairable by local trades (bicycle shops)

we could also talk about as a “target condition.”

Winter describes an iterative design process where the first two attempts failed once they got them into the hands of actual users. A valuable lesson – the only true “voice of the customer” is the customer!

The “Marshmallow Challenge” (in the link back above) describes the power of an iterative process within a constrained design space as well – though the most rapid learning occurs in a group that may surprise you.

A company I worked for got a challenge from Mr. Nakao of Shingijutsu: “Make your next year of aggressive growth with:

  • No more people.
  • No more space.
  • No more money (capital).

In other words, squeeze it out of the waste that is all around you. That was a year of intense learning for all of us, but even today that company has one of the highest value-add per unit of area I have seen in any plant, with operations reaching inventory turns in mid-to-high double digits.

The experience of “constraints driving innovation” also plays out in a client project I have been involved with. They set out a challenge for themselves that was very aggressive – an order of magnitude difference from their current baseline. Then they set out to meet that challenge.

Past history (they tell me) has been to routinely break the “constraints” in these projects, but this time around they are sticking to their own rules.

What has emerged a large wall covered with major sub-goals, each with its criteria (the target condition), the current level of performance, the gap, the next trial they expect to run, the expected result.

They have been working hard to try to reduce the cycle time of those experiments: What can we do with what we have; What can we do for free or cheap rather than waiting until everything is here?

The key point here is that a well focused challenge can align people’s efforts and keep them focused on the objective.

The best challenges are the ones that come from within.

What are you striving for?

Finding Patterns

“What is your target condition?”

“One-by-one flow, meeting an 11 minute planned cycle time, with two people.”

“What is your current condition now?”

“We are making rate, but our lowest repeatable times add up to 28 minutes, and with that and the 32% variation we are seeing, we need 3 people on the line to do it consistently.”

“Where is all of that variation coming from? What are people struggling with?”

“All of the assemblies are different!”

And this was kind of true. We had five different larger assemblies firing in a repeating cycle:

A, B, C, A, D, E, A, B, C, A, D, E

And to make the discussion more interesting, each of these items has four sub-assemblies, of different types, that go into it. This line was building those sub-assemblies in a sequence that matched the need. So it is easy to see why all of that variation seemed overwhelming.

But there was commonality, a lot of it. The operations were very similar, with the differences being things like:

  • A left-hand or right-hand difference.
  • An operation is included, or excluded from a particular sub-assembly.
  • Differences in geometry that had little or no bearing on the actual operations being conducted.

My goal was to lead them to doing more detailed observations, seeing the blind assembly operations, chaotic layout on the bench, the occasional hunt for information, and at this point, the learning curve the assemblers are still coming down as we identify key points.

We are hard-wired to see differences in things – that blade of grass is bent, is there a tiger there? Sometimes it is more challenging to seek out and become aware of the underlying patterns. In other words, what these items have in common.

Rather than looking at obstacles to build the parts, we want to look at the obstacles to smoothly carrying out the operations. It is a subtle difference, but an important one. Sometimes you have to search through the noise to find the signal.

As of this writing, the bench is getting better organized, tools are getting homes, and some assembly aids and tools are being developed to avoid having large fingers trying to get things done in small places.

The work is starting to stabilize enough that the patterns are becoming more visible, which allows capturing the work breakdown in a rational way that can be taught – first the base industrial skills, then the common operations, then the sequence of those operations for specific parts.

We’ll get there.