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    <title>Gemba Panta Rei</title>
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    <updated>2012-02-07T23:24:10Z</updated>
    <subtitle>Kaizen Institute is deeply committed to teaching kaizen, lean manufacturing and related systems for maximizing human potential while minimizing wasted resources. This is our blog.</subtitle>
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<entry>
    <title>2-day Visual Management Workshop at VIBCO</title>
    <link rel="alternate" type="text/html" href="http://www.gembapantarei.com/2012/02/2-day_visual_management_workshop_at_vibco.html" />
    <link rel="service.edit" type="application/atom+xml" href="http://www.gembapantarei.com/mt-atom.cgi/weblog/blog_id=1/entry_id=5500" title="2-day Visual Management Workshop at VIBCO" />
    <id>tag:www.gembapantarei.com,2012://1.5500</id>
    
    <published>2012-02-07T23:14:29Z</published>
    <updated>2012-02-07T23:24:10Z</updated>
    
    <summary>The Lean Enterprise Institute, Rhode Island-based VIBCO and instructor Gwen Galsworth will collaborate to offer the Visual Workplace/Visual Thinking seminar. The format is a combination of classroom and shop-floor learning. Participants will first attend a visual workplace workshop on March...</summary>
    <author>
        <name>Jon Miller</name>
        <uri>http://www.kaizen.com</uri>
    </author>
    
        <category term="Lean Manufacturing" />
    
    <content type="html" xml:lang="en" xml:base="http://www.gembapantarei.com/">
        <![CDATA[<p>The Lean Enterprise Institute, Rhode Island-based VIBCO and instructor Gwen Galsworth will collaborate to offer the <a href="http://bit.ly/z95bTU">Visual Workplace/Visual Thinking seminar</a>. The format is a combination of classroom and shop-floor learning. Participants will first attend a visual workplace workshop on March 27th in Warwick, RI, followed by a visit to VIBCO on March 28th to observe and evaluate its efforts at implementing a visual workplace</p>

<p><a href="http://www.vibco.com/">VIBCO</a> has been on its lean journey since 2004 and sees visual management as an important next step.</p>

<p>The cost for day 1 is $800 and the cost for day 2 is $400. To see complete event details or to register, please <a href="http://bit.ly/z95bTU">visit the LEI website</a>.</p>]]>
        
    </content>
</entry>

<entry>
    <title>Consumption Rate, Replenishment Time, SWIP and Why Glaciers Need Love</title>
    <link rel="alternate" type="text/html" href="http://www.gembapantarei.com/2012/01/consumption_rate_replenishment_time_swip_and_why.html" />
    <link rel="service.edit" type="application/atom+xml" href="http://www.gembapantarei.com/mt-atom.cgi/weblog/blog_id=1/entry_id=5484" title="Consumption Rate, Replenishment Time, SWIP and Why Glaciers Need Love" />
    <id>tag:www.gembapantarei.com,2012://1.5484</id>
    
    <published>2012-01-23T06:37:52Z</published>
    <updated>2012-01-23T07:19:28Z</updated>
    
    <summary> Over the past week the greater Seattle area was met with the largest snowfall in a decade or two. Recently I was in New York City, where the season&apos;s supply of snow had dropped last October, with barely a...</summary>
    <author>
        <name>Jon Miller</name>
        <uri>http://www.kaizen.com</uri>
    </author>
    
    <content type="html" xml:lang="en" xml:base="http://www.gembapantarei.com/">
        <![CDATA[<p><span class="mt-enclosure mt-enclosure-image" style="display: inline;"><img alt="glacier.JPG" src="http://www.gembapantarei.com/glacier.JPG" width="425" height="283" class="mt-image-center" style="text-align: center; display: block; margin: 0 auto 20px;" /></span></p>

<p>Over the past week the greater Seattle area was met with the largest snowfall in a decade or two. Recently I was in New York City, where the season's supply of snow had dropped last October, with barely a blizzard since. Back in November during a train ride through the Alps courtesy of an unexplained Swiss Air cancellation, I saw unseasonably snow-free peaks. Whether or not you believe the science of climate change and the causal link between increased levels of atmospheric carbon and increased temperatures, a lean thinker with a basic understanding of the importance of logically sized levels of stock within the value chain, a.k.a. standard work in process, should be concerned by the evidence that our glaciers are melting into our oceans.</p>

<p>First, a review of the basics of consumption rate, replenishment time, standard work in process (SWIP) and what this means for delivery to the customer. Simply put, if our replenishment time is longer than and asynchronous with the consumption rate of our customer, we need a SWIP reservoir that allows us to build up and draw down stock. This requires that we have the throughput capacity to get ahead of demand in the first place, i.e. by producing while customers sleep. For a detailed explanation of what this means for a complex manufacturing process, <a href="http://www.gembapantarei.com/2007/02/how_to_calculate_standard_work.html">please see this article</a>.</p>

<p>The water cycle and a supply chain balanced with customer consumption rate using SWIP are instances of the same thing. In fact I'm fairly certain that our recently broken global financial system vis a vis the U.S. housing market is nothing more than runaway overproduction (houses) and a shortage of raw materials (cash) fueled be false orders placed into the system (housing bubble). Nature isn't greedy, and doesn't make things overly complicated, so neither should we humans when it comes to systems that we build or influence.</p>

<p>Wondering about the water cycle, melting glaciers, and unusual precipitation, I looked into what some are calling "peak water". Although we won't run out of water in the same way that we can burn up all of the petroleum that we extract from the earth, we may run out of water we can use faster than we think. According to research by Russian hydrologist Igor Alexander Shiklomanov on the distribution of the 1.34 billion cubic kilometers of water on our planet, we have:</p>

<p><strong>96.5%</strong> of water as <strong>salty ocean</strong><br />
<strong>>1%</strong> of water as soil moisture or <strong>inaccessible groundwater</strong><br />
<strong>1.75%</strong> as <strong>glacial ice</strong><br />
<strong><1%</strong> of water is <strong>accessible </strong>for human use</p>

<p>While one might think "Heck, <1% of 1.34 billion cubic kilometers is more water than we'll ever need in our lifetime!" the truth is more sobering. Less than 0.008% of the fresh water is readily accessible in the form our lakes, rivers, dams and rain. And not even all of that is fit for human consumption without treatment.</p>

<p>What about the nearly 2% of water in glaciers? Why not tap that source? This is in fact what the water cycle does. During cold, wet winters water is stored as ice in glaciers and during warmer weather the ice is released as water into streams. The world's glaciers are free reservoirs of freshwater, like tens of thousands of man-made dams. The trouble seems to be some of these glaciers are melting into the salty ocean, increasing the unusable portion of the earth's water supply, even while reducing the SWIP buffer that we rely on for melt-off flow in the spring and summer.</p>

<p>When a supply chain runs itself dry of SWIP, bad things happen. The downstream process must wait for replenishment at full lead-time of the upstream process, or find a quick alternate source of supply. In the raw materials-to-retail supply chain this at most causes a lack of product on the shelf, lost customers and fired supply chain managers. If we are heading towards a drastic depletion in the glacial SWIP from our water cycle, we will face the challenges of finding another source, speeding up the replenishment of our SWIP through some mega-freezing technology, or waiting out the literally glacial lead-time to replenish.</p>

<p>The value stream map is a popular tool but few take it far enough. The typical loops are customer-producer, producer-supplier, and intra-producer. The vast majority of value stream maps look only at the production, distribution and consumption loops, not at the wider and longer-cycle loops such as the replenishment of water, air, raw materials, skilled labor or goodwill. The reward systems of our current business world motivate this. The reality of very long lead-time replenishment is buried in the triangles labeled with the letter "I" for inventory. There seems to be an inexhaustible inventory of minerals, water, topsoil, clean air or free flowing fuel. The most precious materials require glacial or even geologic time to replenish. The Earth doesn't have a graveyard shift it can run to catch up. We ignore the depletion of SWIP at our peril.</p>]]>
        
    </content>
</entry>

<entry>
    <title>10 Rules for Good Gemba Walks</title>
    <link rel="alternate" type="text/html" href="http://www.gembapantarei.com/2012/01/10_rules_for_good_gemba_walks.html" />
    <link rel="service.edit" type="application/atom+xml" href="http://www.gembapantarei.com/mt-atom.cgi/weblog/blog_id=1/entry_id=5492" title="10 Rules for Good Gemba Walks" />
    <id>tag:www.gembapantarei.com,2012://1.5492</id>
    
    <published>2012-01-13T02:20:40Z</published>
    <updated>2012-01-13T05:37:51Z</updated>
    
    <summary> Image source: Wikimedia Commons Elmore Leonard is an American novelist who has been writing lean and taut crime novels for a half century. He is the Toyota of crime novels, if that&apos;s a compliment. Reliable, not flashy, always delivering...</summary>
    <author>
        <name>Jon Miller</name>
        <uri>http://www.kaizen.com</uri>
    </author>
    
        <category term="Tips for Lean Managers" />
    
    <content type="html" xml:lang="en" xml:base="http://www.gembapantarei.com/">
        <![CDATA[<p><span class="mt-enclosure mt-enclosure-image" style="display: inline;"><img alt="elmore leonard.jpg" src="http://www.gembapantarei.com/elmore%20leonard.jpg" width="422" height="374" class="mt-image-center" style="text-align: center; display: block; margin: 0 auto 20px;" /></span> <div style="text-align: center;"><small><small><small>Image source: Wikimedia Commons</small></small></small></div></p>

<p>Elmore Leonard is an American novelist who has been writing lean and taut crime novels for a half century. He is the Toyota of crime novels, if that's a compliment. Reliable, not flashy, always delivering on the promise of a hard-boiled reading experience. He does it by sticking to a process called Elmore Leonard's 10 Rules of Good Writing. They are:</p>

<p>1. Never open a book with weather<br />
2. Avoid prologues<br />
3. Never use a verb other than "said" to carry dialogue<br />
4. Never use an adverb to modify the verb "said"...he admonished gravely<br />
5. Keep your exclamation points under control. You are allowed no more than two or three per 100,000 words of prose<br />
6. Never use the words "suddenly" or "all hell broke loose"<br />
7. Use regional dialect, patois, sparingly<br />
8. Avoid detailed descriptions of characters<br />
9. Don't go into great detail describing places and things<br />
10. Try to leave out the part that readers tend to skip</p>

<p>Skip it. Avoid it. Leave it out. Never touch the stuff. Don't be tempted. Stick to the story. Succeed through subtraction. This man is a lean thinker. And he bears an uncanny physical resemblance to both John Shook and James Womack, after they borrowed some hair from Mike Rother. If Elmore Leonard cared what a gemba walk was, he might say something like this:</p>

<p>1. <strong>Never open a gemba walk dialogue with weather</strong>. Show some respect for the people you are talking to on the gemba. Know who they are, know something about them, ask about their kids, their hobby, their dog, whatever lights up their life.</p>

<p>2. <strong>Avoid prologues</strong>. Don't spend time explaining who you are or why you are walking the floor and asking questions. If you need to this, you don't trust them or they don't trust you. If they are surprised to see you, that's a problem. Build trust first.</p>

<p>3. <strong>Never use an interrogative other than "why?" to carry dialogue.</strong> Go ahead and use the other interrogatives such as "what" and "how" to start the dialogue. Stick with "why" to carry the dialogue forward. You're on a gemba walk to identify lack of standards, standards that are not attainable or standards not being followed, and engage people in thinking about why this is so. Encourage them to find creative solutions to these problems.</p>

<p>4. <strong>Never use the word "not" to modify the interrogative "why?"</strong> You're smart, maybe you're in a position of power. It's terribly tempting to show that by giving answers. You're not on a gemba walk to solve problems. Insted, develop the sensitivity to see everyday problems, the skills to solve problems creatively, in a scalable way. People expect leaders to solve problems. Your "why not..?" robs them of an opportunity to come up with solutions themselves. Let them learn how to fix it, even if it takes longer.</p>

<p>5. <strong>Keep your "a-ha!" moments under control.</strong> You are allowed no more than two or three per 100,000 steps of gemba walking. If you're doing a whole lot more learning, you might need to go back to kaizen school before you're ready to teach. Or maybe just keep walking.</p>

<p>6. <strong>Never use the words "maybe" or "I guess."</strong> You're solving problems again. Stop speculating. See rule #3.</p>

<p>7. <strong>Use technical terms, jargon, sparingly.</strong> Speak in code only if you want to keep secrets. Speak the language of the floor. Listen with an open mind to whatever lessons it will yield. Humble yourself on the gemba walk and become the learner.  </p>

<p>8. <strong>Avoid detailed descriptions of problems.</strong> You're walking the gemba to check the level of understanding of the problem solving process, not whether they have the right solution. The right process yields the right results.</p>

<p>9. <strong>Don't ask people for great detail in describing places and things.</strong> Take a healthy interest in the workplace, the product, the process. Don't let curiosity take over and lose focus on the purpose of the gemba walk. It's not industrial tourism.</p>

<p>10. <strong>Try to leave out the part that customers tend to skip.</strong> You know, the non value added parts. Oh, that's most of your operation? Sorry. You better get busy with kaizen.</p>

<p>This one goes out to my friend BHC. Deep down, you're pretty hard-boiled. Thanks for the encouragement.</p>]]>
        
    </content>
</entry>

<entry>
    <title>Kanban: the Art of the Japanese Shop Sign</title>
    <link rel="alternate" type="text/html" href="http://www.gembapantarei.com/2012/01/kanban_the_art_of_the_japanese_shop_sign.html" />
    <link rel="service.edit" type="application/atom+xml" href="http://www.gembapantarei.com/mt-atom.cgi/weblog/blog_id=1/entry_id=5483" title="Kanban: the Art of the Japanese Shop Sign" />
    <id>tag:www.gembapantarei.com,2012://1.5483</id>
    
    <published>2012-01-05T04:56:47Z</published>
    <updated>2012-01-05T05:54:59Z</updated>
    
    <summary> The kanban has met many adventures on its way to becoming a popular tool for the limitation of tasks, projects and works in process. As superhero origin stories go, kanban has an interesting one. As long ago as 8th...</summary>
    <author>
        <name>Jon Miller</name>
        <uri>http://www.kaizen.com</uri>
    </author>
    
    <content type="html" xml:lang="en" xml:base="http://www.gembapantarei.com/">
        <![CDATA[<p><span class="mt-enclosure mt-enclosure-image" style="display: inline;"><img alt="kanban the art of japanese shop sign.png" src="http://www.gembapantarei.com/kanban%20the%20art%20of%20japanese%20shop%20sign.png" width="287" height="319" class="mt-image-center" style="text-align: center; display: block; margin: 0 auto 20px;" /></span></p>

<p>The kanban has met <a href="http://www.gembapantarei.com/2009/06/the_amazing_adventures_of_kanban.html">many adventures</a> on its way to becoming a popular tool for the limitation of tasks, projects and works in process. As superhero origin stories go, kanban has an interesting one. As long ago as 8th century Japan, guidelines were set down for the forms and functions of kanban as corporate logos and shop signs. Just as the study of the use and evolution of forms of kanban as an improvement tool is illustrative as to the development of management various industries from manufacturing to software development, an examination of kanban as Japanese shop signs is instructive of the historical and cultural changes that took place.</p>

<p>The book Kanban: the Art of the Japanese Shop Sign by Dana Levy, Lea Sneider and Frank Gibney, may be of interest to the fan of Asian history, art, kaizen or software development, in decreasing order. If you are a kanban devotee and resident of King County, Washington you can find it in the public library. Frankly there is not much of use in this book to a lean practitioner or coder with a colorful whiteboard. However the book is full of hundreds of beautiful photographs of antique sign boards, each embodying the spirit of the times. </p>

<p>The thirty pages of commentary give a view into Japanese history through the keyhole of the merchant class. One passage which was deliciously ironic:</p>

<p><em><blockquote>To most merchants, profits were secondary to increasing one's share of the market and thus insuring the growth and permanency of the senior merchant house - an interesting portent of modern Japanese multinational business strategies.<br />
</blockquote></em></p>

<p>The kanban as sign board in feudal Japan was in fact created originally to stimulate consumption and demand, to drive revenue growth through ostentatious displays and ornamentation. The kanban system was devised by Taiichi Ohno to stop overproduction, to limit supply and match it as closely as possible to downstream customer demand, using a humble paper tag rather than material requirements planning and execution software system. </p>

<p>Oh kanban, how far you have traveled.</p>]]>
        
    </content>
</entry>

<entry>
    <title>Leaning Into 2012</title>
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    <link rel="service.edit" type="application/atom+xml" href="http://www.gembapantarei.com/mt-atom.cgi/weblog/blog_id=1/entry_id=5481" title="Leaning Into 2012" />
    <id>tag:www.gembapantarei.com,2012://1.5481</id>
    
    <published>2012-01-01T09:00:31Z</published>
    <updated>2012-01-01T09:38:55Z</updated>
    
    <summary> Many years ago when I was first learning how to drive a car, my dear young aunt Ruth rode with me on an Illinois country road. She taught me the importance of accelerating when going into a curve. This...</summary>
    <author>
        <name>Jon Miller</name>
        <uri>http://www.kaizen.com</uri>
    </author>
    
        <category term="Tips for Lean Managers" />
    
    <content type="html" xml:lang="en" xml:base="http://www.gembapantarei.com/">
        <![CDATA[<p><span class="mt-enclosure mt-enclosure-image" style="display: inline;"><img alt="leaning into the race.JPG" src="http://www.gembapantarei.com/leaning%20into%20the%20race.JPG" width="402" height="266" class="mt-image-center" style="text-align: center; display: block; margin: 0 auto 20px;" /></span></p>

<p>Many years ago when I was first learning how to drive a car, my dear young aunt Ruth rode with me on an Illinois country road. She taught me the importance of accelerating when going into a curve. This was deeply counter intuitive to me, as I had previously always tapped the breaks when hitting a curve in the road. I'm no race car driver, but this lesson has stuck with me, and I think of her whenever drivers tap their breaks on the local highway S-curves, a cascade creating completely unnecessary traffic slowdowns.</p>

<p>This year, more than any year in memory, is starting off both with curves and increasing momentum. I am looking forward to the challenges and learning opportunities ahead for us in Kaizen Institute. Mentally, I am leaning into 2012. Just as my aunt Ruth taught me, it is a time to be fully engaged in the process of change, driving forward faster even when the road changes course.</p>

<p>This got me thinking about the popular expression of "lean forward" and "lean back" entertainment, and whether the definition of "lean" as a business practice might not benefit from the other definition, meaning to incline in a direction. A "lean forward" medium such as the personal computer or internet requires a certain level of interaction, intent and engagement while a "lean back" medium such as television or radio requires only passive attention, and not even full attention at that. Similarly, lean management is approached by some in a lean-forward-and-engage way and by others in a lean-backward-and-watch way.</p>

<p>Lean management is about both acceleration and change. It requires that the drivers and leaders lean into the process, rather than frequently tap the breaks, confuse those who follow and cause the organizational equivalent of the dreaded S-curve slowdown. The only way leaders can accelerate change is to engage in it themselves, to get a feel for both the vehicle and the road, leading by example before delegation. All levels within an organization must lean into it, everyone must be involved in kaizen.</p>

<p>Practically speaking, this means going back to the basics and checking that customer expectations, standards, visuals, zones of control, objectives, team norms, responsibilities and lines of communication are all clear and direct. If you have to ask, it's not clear enough. This means removing barriers to making improvement, often meaning that we must take time to break down larger problems into smaller, more actionable ones. At other times, it means removing whatever wall, policy, prop or paradigm that people are leaning against, leaning back in disengagement. Leaning forward, even when we fall, we have a chance to right ourselves and make stumbling progress.</p>

<p>May your roads be as straight and smooth as the ones running through Illinois corn country, may the grip of your wheels be firm and your acceleration smooth when the earth inevitably curves beneath you.</p>

<p>Happy 2012.</p>]]>
        
    </content>
</entry>

<entry>
    <title>The 5th Myth about the Respect for People Principle</title>
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    <link rel="service.edit" type="application/atom+xml" href="http://www.gembapantarei.com/mt-atom.cgi/weblog/blog_id=1/entry_id=5474" title="The 5th Myth about the Respect for People Principle" />
    <id>tag:www.gembapantarei.com,2011://1.5474</id>
    
    <published>2011-12-08T03:23:44Z</published>
    <updated>2011-12-08T03:26:52Z</updated>
    
    <summary> In an excellent blog post by Jamie Flinchbaugh today he introduces 4 myths about the principle of &quot;Respect for People&quot;, saying: But respect for people means different things to different people. To some it means avoiding layoffs at all...</summary>
    <author>
        <name>Jon Miller</name>
        <uri>http://www.kaizen.com</uri>
    </author>
    
        <category term="Tips for Lean Managers" />
    
    <content type="html" xml:lang="en" xml:base="http://www.gembapantarei.com/">
        <![CDATA[<p><span class="mt-enclosure mt-enclosure-image" style="display: inline;"><img alt="respect for people.png" src="http://www.gembapantarei.com/respect%20for%20people.png" width="201" height="286" class="mt-image-center" style="text-align: center; display: block; margin: 0 auto 20px;" /></span></p>

<p>In an excellent blog post by Jamie Flinchbaugh today he introduces <a href="http://jamieflinchbaugh.com/2011/12/4-myths-about-the-principle-of-respect-for-people/?utm_source=twitterfeed&utm_medium=twitter">4 myths about the principle of "Respect for People"</a>, saying:</p>

<p><em><blockquote>But respect for people means different things to different people. To some it means avoiding layoffs at all costs. To others it means giving them freedom to do whatever they want, or assume that they are right. To others it means trust. In all, I see the principle of respect for people thrown about sometimes casually, and sometimes in direct conflict of what I believe the principle is truly about.</blockquote></em></p>

<p>Building on this theme, I offer a 5th myth.</p>

<p><strong>5. Removing the "8th Waste" means utilizing people's creative ideas for kaizen.</strong></p>

<p>The so-called 8th waste of human potential is often used as an underpinning for employee involvement programs, suggestions systems, and other means of tapping people's unused creative potential. These things are essential, but is this truly respect for the person? This ultimately goes back to a resource utilization mindset, i.e. "What can the employee do to help reduce cost for the company with their creative ideas?" While smart companies like Toyota use kaizen suggestions and quality circles more to develop problem solving skills then to find big cost savings, this interpretation of respect for people via exploitation of the 8th waste only addresses half of human potential at best, the quantitative half.</p>

<p>When we start removing the 8th waste, stop ignoring people as idea generators, listen and put into practice their kaizen suggestions, we are engaging more of a person's potential. It is an quantitative improvement. Instead of only physical ability or trained-in job skills, we are making use capacity for creativity, problem solving and so forth. But more thought and more action does not necessarily mean better throught and better action. In fact if an evil overlord succeeds in removing the 8th waste and in empowering his underlings to find more creative ideas for subjugating the masses of the world, this is a bad thing from the view of the majority of humanity.</p>

<p>It is not so much the productive output, the quality of workmanship or even the number of innovative or cost savings ideas that gives us a true sense of what it means to practice respect for people in the widest sense. We must maximize the <em>good</em> that people can do as a result of their work, i.e. serving people. This is too often totally missing from the respect for people discussion associated with lean. Eliminate waste, continuously improve, pursue perfection... to what end?</p>

<p>Although it may seem pre-industrial to argue for ethics as part of the education and management of a workplace, work is where most of us spend more than a third of our waking time. Another third, likely not in ethics class but sinning or striving to do good as one will. And the final third, we sleep, dream to sort and file the impressions made in our mind during the day while we rest our bodies. When, if not at work, can we practice the ethics of service to people? How better to demonstrate respect for humanity?</p>

<p>The respect for people principle must be applied not only to people within the company but to customers and broader society, extended to what some call Corporate Social Responsibility. Firms that fail to embody and teach ethics to their people will ultimately be rejected by societies that value ethics. The same is true for political or social organizations which fail to act in fair and ethical ways; society rejects them through self-organizing protest movements. </p>

<p>The 5th myth is that respect for people can be demonstrated simply by further teaching and practice of kaizen, or investing more in self-directed teams and front-line empowerment. This is easier to understand if one reflects on the original meaning of kaizen which is not simply "improvement", i.e. change for the better, but change for good.</p>

<p>This is an important topic so I encourage readers to leave comments with their 6th, 7th or 8th myth about respect for people. I encourage other bloggers to pick up the theme, linking to previous articles on this subject, starting with Jamie's and my. Let's start a virtuous circle of discussion to deepen our practical understanding of the respect for people principle.</p>]]>
        
    </content>
</entry>

<entry>
    <title>Kaizen and the Moisture Content of Fabrics</title>
    <link rel="alternate" type="text/html" href="http://www.gembapantarei.com/2011/12/kaizen_and_the_moisture_content_of_fabrics.html" />
    <link rel="service.edit" type="application/atom+xml" href="http://www.gembapantarei.com/mt-atom.cgi/weblog/blog_id=1/entry_id=5471" title="Kaizen and the Moisture Content of Fabrics" />
    <id>tag:www.gembapantarei.com,2011://1.5471</id>
    
    <published>2011-12-02T21:08:53Z</published>
    <updated>2011-12-02T21:22:43Z</updated>
    
    <summary> Fabric is one of the oldest technological artifacts of humanity. Water is essential to our survival and ubiquitous in our daily lives. So it is fitting that these two things come together in a metaphor about kaizen - changing...</summary>
    <author>
        <name>Jon Miller</name>
        <uri>http://www.kaizen.com</uri>
    </author>
    
        <category term="Kaizen" />
    
    <content type="html" xml:lang="en" xml:base="http://www.gembapantarei.com/">
        <![CDATA[<p><span class="mt-enclosure mt-enclosure-image" style="display: inline;"><img alt="fabric.png" src="http://www.gembapantarei.com/fabric.png" width="445" height="336" class="mt-image-center" style="text-align: center; display: block; margin: 0 auto 20px;" /></span></p>

<p>Fabric is one of the oldest technological artifacts of humanity. Water is essential to our survival and ubiquitous in our daily lives. So it is fitting that these two things come together in a metaphor about kaizen - changing things for the better.</p>

<p><strong>The Wet Blanket</strong></p>

<p>Our friend and contributor S.M. Junaid observed ten deadly hurdles to doing kaizen within in small and medium-sized companies. These he calls "wet blankets". A wet blanket is typically a person who takes the fun out of a situation for others. Perhaps it came from the use of water-logged blankets to put out unwanted fires.</p>

<p>Junaid extends the wet blanket idiom to a set of expressions people use when they feel uncomfortable supporting or participating in change. Such people may purposely put "wet blankets" on the kaizen effort or try to persuade senior management that improvement efforts should be stopped.</p>

<p>Here are some examples of wet blankets that Junaid has heard:<blockquote></p>

<p>1.	We have tried it before and it didn't work<br />
2.	Nobody else is doing it<br />
3.	Nobody is talking about it<br />
4.	It's not acceptable to management <br />
5.	It's not in the budget<br />
6.	You're not the expert<br />
7.	Who do you think you are?<br />
8.	Let me think about it.<br />
9.	Do you know more than me?<br />
10.	This is not your concern</blockquote></p>

<p>Junaid writes: </p>

<blockquote>How will we move towards improvement with these 10 deadly hurdles? It is on your choice and devotion that you will only do your plain job or an effective job in your organization, without kaizen your job is not valuable for you and your organization in long-term basis.

<p><br />
My experience is that it is better to move slowly but continuously towards improvement, not strike or jump the hurdle as this may cause harm. The only a tool you have is determination. If you see any hurdle in your way slightly change your path but don't stop moving forward. Cross the hurdle and again put your feet on track and move toward your destination.</p>

<p>Do kaizen again, again and again at last the wet blanket becomes dry.</blockquote></p>

<p>The idea of the wet blanket reminded me of a couple of other expressions related to kaizen and the moisture content of fabrics. </p>

<p><strong>The Dry Towel</strong></p>

<p>After decades of kaizen, people at Toyota speak their efforts at cost reduction as being like "wringing the water from of a dry towel". This is hard to do, unless you use that towel to go mop up moisture (problems) in a totally new area. There is still a lot of water on the floor even at Toyota, looking across the entire extended value stream from retail and distribution back through supply chain and design. In fact there is no reason whatsoever to limit the search for moisture to within the enterprise value stream. Many businesses who have developed kaizen capabilities, such as Toyota, Boeing and Group Health to name just a few, share these resources with not-for-profit and public sector causes. If you have a dry towel, know how to use it, and have time, go mop something up..</p>

<p><br />
<span class="mt-enclosure mt-enclosure-image" style="display: inline;"><img alt="sponge kaizen.jpg" src="http://www.gembapantarei.com/sponge%20kaizen.jpg" width="338" height="240" class="mt-image-center" style="text-align: center; display: block; margin: 0 auto 20px;" /></span><br />
<strong>The Sponge</strong></p>

<p>Although technically not a fabric but the porous and dried out bodies of sea animals, one of my <em>sensei </em> asked an American manager who was too smart for his own good to "become a sponge". The message was to open up and absorb everything instead of being a wet blanket who questions everything intellectually and critically, finding fault. </p>

<p>"A sponge doesn't have a brain! It doesn't move! It just absorbs!" said the <em>sensei</em>, waving a soft porous block in emphasis. </p>

<p>The manager then pointed out that <em>sensei</em> was mixing metaphors between the sea animal and the household cleaning tool. This verbal judo only made the <em>sensei's</em> demand more firmly that he be "brainless and motionless" for a spell. </p>

<p>Standing in the circle is not enough, it is necessary to enter the circle not as a damp cloth but as a dry sponge.</p>]]>
        
    </content>
</entry>

<entry>
    <title>Live Seminar: Built-in Quality, Dallas - Dec. 5, 2011</title>
    <link rel="alternate" type="text/html" href="http://www.gembapantarei.com/2011/11/live_seminar_built-in_quality_dallas.html" />
    <link rel="service.edit" type="application/atom+xml" href="http://www.gembapantarei.com/mt-atom.cgi/weblog/blog_id=1/entry_id=5464" title="Live Seminar: Built-in Quality, Dallas - Dec. 5, 2011" />
    <id>tag:www.gembapantarei.com,2011://1.5464</id>
    
    <published>2011-11-28T13:55:00Z</published>
    <updated>2011-11-29T02:02:16Z</updated>
    
    <summary>Peterbilt Motors, Gemba Academy and Kaizen Institute are pleased to present a half-day live workshop on Monday December 5th 2011 on the subject of &quot;Built-in Quality&quot;, one of the two pillars of the Toyota Production System house. Sometimes called jidoka...</summary>
    <author>
        <name>Jon Miller</name>
        <uri>http://www.kaizen.com</uri>
    </author>
    
        <category term="Kaizen" />
    
    <content type="html" xml:lang="en" xml:base="http://www.gembapantarei.com/">
        <![CDATA[<p>Peterbilt Motors, Gemba Academy and Kaizen Institute are pleased to present a half-day live workshop on Monday December 5th 2011 on the subject of "Built-in Quality", one of the two pillars of the Toyota Production System house. </p>

<p>Sometimes called <em>jidoka </em>or autonomation, the lean approach to quality is to develop processes that prevent, detect, contain and countermeasure errors. The aim of a Built-in Quality system is to stop defects from being passed to the next process i.e. the customer. Commonly expressed "Don't accept, make or pass on poor quality" this is possible only by understanding how various principles and tools interact within a Built-in Quality system. These enablers include the andon system, the stop-and-call / stop-and-fix principle, Quality Key Points within standardized work, rapid response teams, practical problem solving, mistake proofing, process capability and many others. </p>

<p><span class="mt-enclosure mt-enclosure-image" style="display: inline;"><img alt="Chris Schrandt.jpg" src="http://www.gembapantarei.com/chris%20schrandt.jpg" width="98" height="96" class="mt-image-left" style="float: left; margin: 0 20px 20px 0;" /></span>The seminar speaker will be Chris Schrandt, Senior Consultant with <a href="http://us.kaizen.com">Kaizen Institute</a>. Chris has taught kaizen and the Toyota Production System (TPS) for the past 23 years in the USA, Brazil, Argentina, Sweden and Mexico in manufacturing, healthcare and service fields. Chris gained a deep understanding of Built in Quality over 10 years as Quality Engineering Manager with Toyota in Georgetown, Kentucky. He learned under Japanese coordinators and experts, and directed a team of 40 engineers and support staff responsible for improvement projects across multiple suppliers and processes.                            </p>

<p><strong>Date, Time & Location</strong></p>

<p>Monday, December 5, 2011<br />
0800AM - 1330PM (lunch provided)<br />
Peterbilt Motors Company<br />
3200 Airport Road<br />
Denton, Texas USA</p>

<p><strong>Cost</strong></p>

<p>The cost is $150 per person, including lunch and printed materials.</p>

<form action="https://www.paypal.com/cgi-bin/webscr" method="post">
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<p><br />
We hope to see you there!</p>]]>
        
    </content>
</entry>

<entry>
    <title>Review of Moving Forward Faster by Bob Emiliani</title>
    <link rel="alternate" type="text/html" href="http://www.gembapantarei.com/2011/11/review_of_moving_forward_faster_by_bob_emiliani.html" />
    <link rel="service.edit" type="application/atom+xml" href="http://www.gembapantarei.com/mt-atom.cgi/weblog/blog_id=1/entry_id=5321" title="Review of Moving Forward Faster by Bob Emiliani" />
    <id>tag:www.gembapantarei.com,2011://1.5321</id>
    
    <published>2011-11-26T19:32:01Z</published>
    <updated>2011-11-27T07:42:55Z</updated>
    
    <summary> Bob Emiliani is the author of ten books, six of them in the Real Lean series. The most recent title Moving Forward Faster: The Mental Evolution from Fake Lean to REAL Lean is an executive summary of these six...</summary>
    <author>
        <name>Jon Miller</name>
        <uri>http://www.kaizen.com</uri>
    </author>
    
        <category term="Book Reviews" />
    
    <content type="html" xml:lang="en" xml:base="http://www.gembapantarei.com/">
        <![CDATA[<p><a href="http://www.bobemiliani.com/b3mff.html"><span class="mt-enclosure mt-enclosure-image" style="display: inline;"><img alt="moving forward faster book.png" src="http://www.gembapantarei.com/moving%20forward%20faster%20book.png" width="150" height="231" class="mt-image-center" style="text-align: center; display: block; margin: 0 auto 20px;" /></span></a></p>

<p>Bob Emiliani is the author of ten books, six of them in the Real Lean series. The most recent title <a href="http://www.bobemiliani.com/b3mff.html">Moving Forward Faster: The Mental Evolution from Fake Lean to REAL Lean</a> is an executive summary of these six books. It is 100 pages, about half of which is the core message structured around 40 pages of bullets on four themes to aid in the "mental evolution" of executives towards real lean thinking. The remaining pages are closing thoughts, next steps and rich appendices.</p>

<p>The lean management system is, in Bob Emiliani's words, "a non-zero-sum principle-based management system focused on creating value for end-use customers and eliminating waste, unevenness, and unreasonableness using the scientific method." His Real Lean series of books makes its greatest contribution in stressing the Respect for People principle as the least appreciated and least practiced by executives. The Moving Forward Faster book is best read as an introduction to Bob's thinking, and as a reference for diving deeper into his ideas. </p>

<p>Across four chapters Bob debunks 85 commonly held beliefs in the Economic, Social, Political (organizational) and History arenas. Each of these ideas are explained using as few as two and as many as nine bullet points. The sheer number of bullet points across the 40 pages will leave one dizzy if the four chapters are are read in one go. It is possible to open the book at almost any point, read a few sentences, nod in agreement or shake our heads in recognition of fake lean behaviors within our own organizations. </p>

<p>In the section on Economic ideas, Bob asks "Where are the lean economists?" and points out that economics is a social science rather that a hard science like physics or mathematics, and that formal root cause analysis is never used to discern sources of failure of economic theories. This is a big idea, considering that some of the most important decisions in our lives vis a vis our life in "the economy" are influence by social scientists who never practice root cause analysis. In any case some of the most interesting and important ideas are in this section. Here is a sampling of the gems.</p>

<p>E10 - Short-term financial focus</p>

<blockquote>When do you plan on going out of business? If the answer is never, then why have a strong short-term focus?</blockquote>

<p>It's a great point, but misses the fact that executives many times aren't thinking at all about business continuity or the long-term because that is not what they are rewarded for or paid to do. Or perhaps it is not a rhetorical question but an invitation to the reader to list their reasons.</p>

<p>E16 - Fixation on unit costs and unit prices.</p>

<blockquote>Executives say: "Every cost element a company faces needs to be examined." Executives should instead say: "Every process a company uses needs to be examined." Costs are subordinate to processes.</blockquote>

<p>And Taiicho Ohno said, "Costs do not exist to be calculated. Costs exist to be reduced." </p>

<p>E20 - Cost is not real if it is not on a spreadsheet.</p>

<blockquote>Cost = measured cost + unmeasured cost. Unmeasured cost is always greater than zero. Just because some costs do not show up on a spreadsheet does not mean they do not exist.</blockquote>

<p>Taiichi Ohno would have gone to the gemba to see the costs, never to a spreadsheet. Anyone bringing him a spreadsheet would have soon found themselves standing in a circle.</p>

<p>E24 - Must grow at double-digit rates.</p>

<blockquote>Strive for stable long-term growth: 2-3 percent annual growth.</blockquote>

<p>The percentage for stable long-term growth of an organization's revenue would seem to depend on various factors including competition, the available local market, disruptive innovations reducing revenue from existing products, changes in demographics leading to changes in organic demand, changes in tax rates, rate of inflation in fixed and variable costs, etc. Granted that Bob Emiliani starts out by saying that economics is a social science and not one that is build on fact-based confirmation of theories, this theory or claim of 2-3 percent being an adequate growth rate begs further explanation, perhaps found in one of the Real Lean books.</p>

<p>The section on Social Ideas that Must Diminish or be Eliminated puts various universal organizational principles in context of how misguided executive thinking can cause lean failures. These ideas include but are not limited to misconceptions about teamwork versus individualism, blaming people, standardization, job descriptions, excessive gaps in compensation, excessive gaps between words and actions, and the focus for executives on learning rather than having answers. This may be the most accessible chapter, dealing largely with actionable personal behaviors or beliefs of executives, such as:</p>

<p>S12 - Leaders are smarter than followers.</p>

<blockquote>Leaders know much less than they think because information is highly filtered to deliver only good news.</blockquote>

<p>In the Politics section Bob makes a case for executives to eliminate organization politics in that this enables a freer flow of material and information, resulting in better decisions, actions and results. The section on History is almost entirely a list of non-lean behaviors of managers, centering around the failure to listen to stakeholders, attempt to solve problems at the root cause level, and to learn.<br />
 <br />
The four Appendices sections are definitely not to be skipped over. In fact, they could easily have been within the main flow of the book, rather than at the end. The notion of Feral Managers may offend some readers who recognize these traits in themselves, but everyone has met at least one wild, out-of-control executive, and we could all do with fewer. The assessment form and instructions in Appendix IV is a good opportunity for self-examination by executives and organizations, from a behavioral and mental angle, as opposed to the typical tool or system-based lean assessment. Designed as a "failure analysis" method, Bob Emiliani shared with me that it was intended as an aid in reducing human suffering.</p>

<p>It was a challenging book at first reading because of its structure. However on second reading, 8 months later, the content proved solid and durable, begging further description and discussion. Luckily for that purpose, we have Real Lean volumes 1 through 6. </p>

<p>The target audience is executives, however it is far more likely that this book will be read by non-executives, if only for the simple reason that there are far more of them in the world. For the open-minded executive this book offers many challenges to firmly held notions of economics, history, politics and society that guide but limit the organization's performance. The book invites the reader to understand why these ideas are contrary to "real lean". For the non-executive reader, it provides a glimpse into many of the principles that govern why corporations and executives do many things that are contrary to a lean culture.</p>]]>
        
    </content>
</entry>

<entry>
    <title>Batch Answers to Reader Questions</title>
    <link rel="alternate" type="text/html" href="http://www.gembapantarei.com/2011/11/batch_of_reader_questions_answered.html" />
    <link rel="service.edit" type="application/atom+xml" href="http://www.gembapantarei.com/mt-atom.cgi/weblog/blog_id=1/entry_id=5468" title="Batch Answers to Reader Questions" />
    <id>tag:www.gembapantarei.com,2011://1.5468</id>
    
    <published>2011-11-24T03:39:23Z</published>
    <updated>2011-11-24T08:45:57Z</updated>
    
    <summary> I haven&apos;t kept up so well with reader questions over the past few months so here is a batch of answers. Better late than never, hopefully. A question posted to Quick changeover and SMED for the office: in point...</summary>
    <author>
        <name>Jon Miller</name>
        <uri>http://www.kaizen.com</uri>
    </author>
    
        <category term="Ask Gemba" />
    
        <category term="Kaizen" />
    
    <content type="html" xml:lang="en" xml:base="http://www.gembapantarei.com/">
        <![CDATA[<p><span class="mt-enclosure mt-enclosure-image" style="display: inline;"><img alt="batch answers to questions.JPG" src="http://www.gembapantarei.com/batch%20answers%20to%20questions.JPG" width="368" height="263" class="mt-image-center" style="text-align: center; display: block; margin: 0 auto 20px;" /></span></p>

<p>I haven't kept up so well with reader questions over the past few months so here is a batch of answers. Better late than never, hopefully.</p>

<p>A question posted to <a href="http://www.gembapantarei.com/2007/03/quick_changeover_and_smed_for.html">Quick changeover and SMED for the office</a>:</p>

<blockquote><em>in point "1. Separate internal and external time" A knowledge work example of external set up could be as simple as having the next task or project prepared and waiting for you in a folder so that you could get to it right away, rather than having to go seek out the instructions and information to start the next project smoothly. But my question is how can we balance between this and over processing (from 7 wastes)? </em>

<p>- Mazen</blockquote></p>

<p>All set up, planning, preparation, work instruction documentation or for that matter management activity could be called non value-added. However, these activities serve the purpose of limiting waste caused by being not prepared, not having clear instructions, etc. so they are not waste per se. I would not say that set up is an example of over processing waste, unless the set up process itself was done with more resource or more complexity than absolutely required. It is a difference between qualitative and quantitative. A process is either waste or value-add / non value-add. If it is one of the latter, it may still contain waste, such as over processing. The difference is that if the process is a complete waste (qualitative) the goal is to cut it out while if it is quantitative (complexity, ambiguity etc) the goal is to reduce inputs to the process but not cut it out completely.</p>

<p>Two questions posted to <a href="http://www.gembapantarei.com/2007/02/how_to_calculate_standard_work.html">How to calculate standard WIP</a>:</p>

<blockquote><em>My question is: How can I use lead time and takt time in hospital warehousing of medical supplies? I currently have a team of 9.5 FTE's. The average scan time (order materials) per person is 31.4 minutes The average time to replenish the patient units are 45 minutes, 277 Par locations. All other tasks total 284 minutes. </em>

<p>- Laurie</blockquote></p>

<p>First of all, to answer the "how" question, lead time and takt time can be used in hospital warehousing of medical supplies to a) balance employee workload to customer demand, b) improve on-time delivery from the warehouse, c) set stocking quantities at point of use locations based on replenishment lead-times, etc. The implied question is "how specifically do I do this based on the team, processing times etc?" but it is completely impossible to answer your question based on the information provided. In order to calculate takt time we need to know net available working time per shift and customer demand per shift. Neither is provided in your question. In order to determine lead time we need to know consumption rate, i.e. customer demand. Once we have that information we will be happy to help.</p>

<blockquote><em>So, my process has a "batch auto cycle", like #4, but my auto cycle is five separate batches due to cycle time limitations. How do I use your calculation for SWIP? Do I divide by five? </em>

<p>- Randall</blockquote></p>

<p>This depends on whether you mean 5 separate sequential batches that are run across multiple shifts or 5 batches that go into a process such as an oven at one time. The simplest way to answer this question is to count how many pieces are in your 5 batches currently. Unless you are consistently running the downstream process out of parts, your current WIP quantity is sufficient or excessive. Don't divide by 5. In order to help you calculate the exact quantity, we would need the machine cycle time, capacity (batch size) per cycle, and cycle time from load through auto cycle and unload. </p>

<p>A question from a post about a <a href="http://www.gembapantarei.com/2008/02/101_kaizen_templates_takt_time_calculator.html">takt time calculator</a>:</p>

<blockquote><em>Hi, i have question on how to calculate takt time. A demand of product A is 1000 nos. It takes 2 shifts (8hrs) and 1 hour break to get it done. For the first shift usually takes 20-30 minutes to warm up the machine for the initial process. How should I count the cycle time for the initial process? And how should I count the total cycle time if it involves 2 shift then? </em>

<p>- Jason</blockquote></p>

<p>It sounds like the 20-30 min warm up time could be counted either as set up time and be deducted from the available time for that shift, or it could be handled before the start of the shift so that when day shift crew came in the machine was warmed up and ready to go. If you choose the first option, the takt time calculation is net available time per shift / demand per shift. If the demand for 2 shifts is 1000 and the net regular hours per shift is 8 then the calculation would be (60 min x 8 hrs x 2 shifts) / 1000. If you start warming up the machine when the shift starts, deduct 30 min from available time. In many cases a small crew or the supervisor will come in early to get the machine warmed up so people and materials aren't waiting, in which case you would not deduct the 30 min. When you are calculating takt time, the information "it takes ...min" to get the work done is not necessary. It might take 9 hours based on current conditions, but we set takt by customer demand and then balance or improve our process to get the work done at the pace the customer wants. That information is used after takt time is calculated, to balance the cycle times with takt time. When calculating takt time we only care about net available time and customer demand. </p>

<p>From <a href="http://www.gembapantarei.com/2009/05/8_ways_to_get_total_involvement.html">8 ways to get total involvement</a>:</p>

<blockquote><em>I'm actually working on a project that consists on applying the Kaizen culture in the company I work for. Tough task considering its a company with over 5k employees. I'm aware of all the activities you can perform (5S, suggestion box, TPM, etc), but I'm having a hard time coming up with a way in which people keep being involved, I want them to adopt this way of thinking and not just have them do a couple of activities and then forget this ever happened. Any suggestions?</em>

<p>- Ivan</blockquote></p>

<p>If you can figure out a way to apply the kaizen culture as a project, please let me know!<br />
A kaizen culture transformation is much more than a project, it's a total leadership commitment to changing how people come to work every day. It is management itself. Of course this can be achieved through projects, but be careful not to think that you can "a project" with some kaizen activities and tools and have a new culture. When you do any of the activities mentioned (5S, kaizen suggestions, TPM) properly, you will have employee involvement. Be prepared to support these efforts for at least 12-18 months very closely, making sure the daily management standards are set, followed and improved. Start small, create some wins, build belief, learn from mistakes, etc. Don't worry about changing 5,000 people at first, focus on making sure you have the 50-100 leaders (formal and informal) visibly supporting the kaizen culture. Be careful thinking and talking about the steps to a kaizen culture as "activities" because this implies that you can do 5S as an activity, then stop and move on the next activity. Think of it as building capabilities, system. Most of these things (5S, TPM, suggestion schemes, kanban) are all people-driven systems that live or die by involvement and daily management. Make sure you have the resources and organization to invest time in educating people about the new way of working and why it is important to improve safety, quality, delivery, cost and serve customers. If people do not see kaizen as a way of making their job more interesting, easier etc, they may not be motivated.</p>

<p>Thanks for your questions, it's always fun to hear about your kaizen efforts and challenges.</p>]]>
        
    </content>
</entry>

<entry>
    <title>Free Webinar &quot;Continuous Improvement&quot; Dec. 7, 2011</title>
    <link rel="alternate" type="text/html" href="http://www.gembapantarei.com/2011/11/free_webinar_continuous_improvement_dec_7_2011.html" />
    <link rel="service.edit" type="application/atom+xml" href="http://www.gembapantarei.com/mt-atom.cgi/weblog/blog_id=1/entry_id=5463" title="Free Webinar &quot;Continuous Improvement&quot; Dec. 7, 2011" />
    <id>tag:www.gembapantarei.com,2011://1.5463</id>
    
    <published>2011-11-22T16:32:57Z</published>
    <updated>2011-11-23T01:12:33Z</updated>
    
    <summary>The Visual Management webinar with Kaizen Institute consultant Mike Wroblewski was immensely popular, and we are pleased to announce the next free webinar from Gemba Academy. Webinar: Putting the Continuous Back in Continuous Improvement Wednesday, December 7, 2011, 1400 -...</summary>
    <author>
        <name>Jon Miller</name>
        <uri>http://www.kaizen.com</uri>
    </author>
    
        <category term="Lean Healthcare" />
    
    <content type="html" xml:lang="en" xml:base="http://www.gembapantarei.com/">
        <![CDATA[<p>The Visual Management webinar with Kaizen Institute consultant Mike Wroblewski was immensely popular, and we are pleased to announce the next free webinar from Gemba Academy. </p>

<p>Webinar: <strong>Putting the Continuous Back in Continuous Improvement</strong></p>

<p>Wednesday, December 7, 2011, 1400 - 1500 (Central Time, GMT -6). <a href="http://www.gembaacademy.com/promo/ci-graban.html">Sign up for the webinar</a> </p>

<p>Many organizations have understood the word kaizen to mean "kaizen events," or focused week-long improvement workshops. Innovative healthcare organizations, such as ThedaCare and Virginia Mason Medical Center have learned that kaizen events are not enough, that kaizen must also involve a large number of small, low-cost improvements driven by front-line staff.</p>

<p><span class="mt-enclosure mt-enclosure-image" style="display: inline;"><img alt="mark graban lean healthcare author.jpg" src="http://www.gembapantarei.com/mark%20graban%20lean%20healthcare%20author.jpg" width="100" height="149" class="mt-image-center" style="text-align: center; display: block; margin: 0 auto 20px;" /></span></p>

<p>Mark Graban, who is author of the award-winning book <a href="http://www.leanhospitalsbook.com/">Lean Hospitals</a>, a popular speaker, <a href="http://www.leanblog.org">blogger</a>, a consultant to hospitals and Chief Improvement Officer of <a href="http://www.kainexus.com/home.html">KaiNexus</a>. Mark will share his insights about what it takes to make kaizen successful and sustainable, showing examples of kaizen improvements from numerous healthcare organizations, including the practical mechanics for facilitating and managing kaizen.</p>

<p><a href="Wednesday, December 7, 2011 2:00 - 3:00 pm (Central) Register now - FREE Webinar">Register now - FREE Webinar<br />
</a></p>]]>
        
    </content>
</entry>

<entry>
    <title>Management Improvement Carnival #149</title>
    <link rel="alternate" type="text/html" href="http://www.gembapantarei.com/2011/11/management_improvement_carnival_149.html" />
    <link rel="service.edit" type="application/atom+xml" href="http://www.gembapantarei.com/mt-atom.cgi/weblog/blog_id=1/entry_id=5461" title="Management Improvement Carnival #149" />
    <id>tag:www.gembapantarei.com,2011://1.5461</id>
    
    <published>2011-11-21T07:57:59Z</published>
    <updated>2011-11-21T08:22:30Z</updated>
    
    <summary> I&apos;m honored once again to contribute to the Management Improvement Carnival series which John Hunter at the Curious Cat Management Improvement blog has kept going now to its 149th round. As I looked back over some of the blog...</summary>
    <author>
        <name>Jon Miller</name>
        <uri>http://www.kaizen.com</uri>
    </author>
    
        <category term="Kaizen" />
    
    <content type="html" xml:lang="en" xml:base="http://www.gembapantarei.com/">
        <![CDATA[<p><span class="mt-enclosure mt-enclosure-image" style="display: inline;"><img alt="curious cat 149.JPG" src="http://www.gembapantarei.com/curious%20cat%20149.JPG" width="286" height="438" class="mt-image-center" style="text-align: center; display: block; margin: 0 auto 20px;" /></span></p>

<p>I'm honored once again to contribute to the Management Improvement Carnival series which John Hunter at the <a href="http://management.curiouscatblog.net/">Curious Cat</a> Management Improvement blog has kept going now to its 149th round. As I looked back over some of the blog posts and articles that caught my attention recently, a surprising theme emerged among many of them: motivation.</p>

<p>Motivation is something everyone shares. It is at the root cause of why we do many of the things we do, directly affects our attitude, our effort, our level of success, and therefore eventual happiness. Some organizations measure employee engagement scores, track the number of kaizen suggestions or otherwise attempt to track the level of motivation of people. Motivation is an incredibly valuable input to the success of a team but too often only the results are recognized. Where do we start in building a highly engaged, highly motivated organization?</p>

<p>Addressing the question of "Where do I start?" in learning lean thinking and putting it into practice, Mark Rosenthal suggests adopting the <a href="http://theleanthinker.com/2011/09/07/find-the-bright-spots/">find the bright spots</a> advice from the book Switch. Finding brights spots is always good advice. While companies fail at thing for a wide variety of local and specialized reasons, success tends to cluster around a handful of factors; motivated people; removing waste, variation and burden; a long-term view. We need to drill a level deeper in each one of these. Simply saying "remove waste" is not enough, we need to dig deeper to understand the best practices and "bright spots" at organizations we benchmark to the level where we can put them into practice. We need to learn not only what works well, but why. We need to ask, "What drives or motivates their most successful systems?"</p>

<div style="text-align: right;"><blockquote>Read more from Mark Rosenthal at <a href="http://theleanthinker.com">The Lean Thinker</a>.</blockquote></div>

<p>As things are when it comes to understanding cutting edge management practices, the secret to motivating people is simple, age-old and often counter-intuitive at first glance. One article explains <a href="http://timebackmanagement.com/blog/stop-demotivating-your-employees/">why you don't have to do anything special to motivate employees</a>. Rather, it is a matter of not demotivating people. Just as traditional improvement has focused on increasing the value while ignoring the waste, we need to stop the leaks rather than buy more piping. This is summarized in a quote attributed to Dr. Deming and others:</p>

<p><em><blockquote>If management stopped demotivating their employees then they wouldn't have to worry so much about motivating them.</blockquote></em></p>

<div style="text-align: right;"><blockquote>Read more from Dan Markovitz at <a href="http://timebackmanagement.com/blog/category/timeback-blog/">Time Back Management</a>.</blockquote></div>

<p>On productivity and motivation, one article began by explaining how researchers found that doing or saying something nice, even if this was a very small gesture, has proven to improve the job performance of people including doctors. The premise is that <a href="http://matthewemay.com/2011/11/11/how-positivity-promotes-performance/">positivity promotes performance</a>. This was not so surprising, but the articled also introduced an idea called Appreciative Inquiry, the explanation of which I will truncate to "valuing the best in people [...], as opposed to fixing what's not working". As a firm believer in the importance of concise, constrained and well-worded problem statements struck me as counter to experience. It's proponent Dr. David Cooperrider, of Case Western Reserve University was quoted:</p>

<blockquote><em>Don't get me wrong. I'm not advocating mindless happy talk. Appreciative Inquiry is a complex science designed to make things better. We can't ignore problems--we just need to approach them from the other side.</em></blockquote>

<p>I'm very curious to learn what that "other side" looks like, and how well we can dream and realize a vision of a better future without taking a cold, hard, even at times borderline demotivating look at the root causes of our troubles.</p>

<div style="text-align: right;"><blockquote>Read more by <a href="http://matthewemay.com/">Matthew E. May</a>.</blockquote></div>

<p>The advice to accentuate the positive was counterbalanced by another article in a series on the importance of a leader's grasp on human psychology and <a href="http://bigthink.com/series/70/series_item/4981">how to crush an employee's enthusiasm</a>, a commentary on a video by author and management research Jim Collins. Namely, Collins explains how 3 actions by leaders demotivate people: hype, futurism, and false democracy or appearing to listen to input but not acting on it. Futurism is a failure to link people's day-to-day work and achievements with long-term objectives, and hype is defined as "a failure to acknowledge the real difficulties the organization faces." Dr. Cooperrider agrees that "we can't ignore problems" but Jim Collins warns leaders not to make the future too rosy or the picture too bright, as we may be tempted to "keep things positive" at the expense of working from the brutal facts</p>

<div style="text-align: right;"><blockquote>Read more from various experts at <a href="http://bigthink.com">Big Think</a>.</blockquote></div>

<p>What if things are in turmoil and there is no time to reflect on the positives, paint a rosy picture of the future, and work on motivation - hype or no hype? Often we encounter leaders who say they are too busy with projects or problems and have no time for kaizen - neither to improve processes performance through direct technical intervention nor motivation of people, and certainly not both. <a href="http://www.leanblog.org/2011/09/lack-of-time-for-kaizen-is-a-problem-statement-not-an-excuse/">Lack of time for kaizen is not an excuse</a>, but rather a problem to be studied and countered through effective root cause corrective action. No doubt positive thinking can help in these situations, but practical problem solving is essential to unblock organizations in this state.</p>

<div style="text-align: right;"><blockquote>Read more by Mark Graban at the <a href="http://www.leanblog.org">Lean Blog</a>.</blockquote></div>

<p>In a similar vein, solid advice comes on this topic from another article to <a href="http://jamieflinchbaugh.com/2011/09/call-firefighting-and-band-aids-what-they-are-but-do-them-in-a-structured-way/">call firefighting and band-aids what they are but do them in a structured way</a>. A structured approach to kaizen helps organizations to problem-solve your way out of the vicious circle of "problems > firefighting > no time for root cause correction or capability building > problems > firefighting..." into one that is more stable and in-control.</p>

<div style="text-align: right;"><blockquote>Read more from <a href="http://jamieflinchbaugh.com">Jamie Flinchbaugh</a>.</blockquote></div>

<p>Kevin Meyer found some bright spots on his trip to India and documented them in several fun articles in Evolving Excellence. My favorite was <a href="http://www.evolvingexcellence.com/blog/2011/10/leadership-lessons-from-ganesha.html">leadership lessons from Ganesha</a>, a set of mindsets and behaviors that are both motivating personally and constructive in motivating others.</p>

<div style="text-align: right;"><blockquote>Read more by Kevin Meyer at <a href="http://www.evolvingexcellence.com/blog/">Evolving Excellence</a>.</blockquote></div>

<p><span class="mt-enclosure mt-enclosure-image" style="display: inline;"><img alt="Ganesha shrine.jpg" src="http://www.gembapantarei.com/Ganesha%20shrine.jpg" width="423" height="305" class="mt-image-center" style="text-align: center; display: block; margin: 0 auto 20px;" /></span></p>]]>
        
    </content>
</entry>

<entry>
    <title>Kitchen Jidoka: Low Cost Automation Example</title>
    <link rel="alternate" type="text/html" href="http://www.gembapantarei.com/2011/11/kitchen_jidoka_low_cost_automation_example.html" />
    <link rel="service.edit" type="application/atom+xml" href="http://www.gembapantarei.com/mt-atom.cgi/weblog/blog_id=1/entry_id=5459" title="Kitchen Jidoka: Low Cost Automation Example" />
    <id>tag:www.gembapantarei.com,2011://1.5459</id>
    
    <published>2011-11-19T21:35:51Z</published>
    <updated>2011-11-19T22:11:30Z</updated>
    
    <summary> There are not two but three definitions of the Japanese word jidoka, which students of kaizen and the Toyota Production System are likely to encounter. In fact there are two different jidokas. Coined by Taiichi Ohno as a play...</summary>
    <author>
        <name>Jon Miller</name>
        <uri>http://www.kaizen.com</uri>
    </author>
    
        <category term="Kaizen" />
    
    <content type="html" xml:lang="en" xml:base="http://www.gembapantarei.com/">
        <![CDATA[<p><span class="mt-enclosure mt-enclosure-image" style="display: inline;"><img alt="kitchen karakuri 1.jpg" src="http://www.gembapantarei.com/kitchen%20karakuri%201.jpg" width="344" height="466" class="mt-image-center" style="text-align: center; display: block; margin: 0 auto 20px;" /></span></p>

<p>There are not two but three definitions of the Japanese word jidoka, which students of kaizen and the Toyota Production System are likely to encounter. In fact there are two different jidokas. Coined by Taiichi Ohno as a play on words to turn the Japanese word for "automation" or "self-moving" into "auto<strong>no</strong>mation" or "self-working", the word jidoka and jidoka are pronounced identically, though written slightly differently in Japanese. Please see <a href="http://www.gembapantarei.com/2006/05/the_5_steps_to_building_jidoka.html">previous article</a> for more on jidoka.</p>

<p><span class="mt-enclosure mt-enclosure-image" style="display: inline;"><img alt="jidoka v. jidoka.png" src="http://www.gembapantarei.com/jidoka%20v.%20jidoka.png" width="460" height="117" class="mt-image-center" style="text-align: center; display: block; margin: 0 auto 20px;" /></span></p>

<p>The "self-working" or "auto<strong>no</strong>mation" term is used to kaizen two distinct problems. </p>

<p>First, to separate human work and machine work so that humans can do less non value added and more value added work within a given period of time. For example in a machining process that requires a person to open the door of a CNC machine, unload a part, loads another part and close the door, three out of four of these steps can be done by the machine. The only work that requires the human touch is loading the part, and perhaps doing a visual check. This type of automation is typically done in a low-cost manner. Automating the final step of loading and inspection is higher cost, and not the kaizen way.</p>

<p>Second, auto<strong>no</strong>mation is used to prevent processes from making error after error by building in en error prevention or detect-and-stop functions. Jidoka gives the process the equivalent of the human autonomic nervous system, which can respond to stimuli without conscious thought. This can take the form of sensors on a machine, lines of code that mistake proof a data entry field, or a button pressed by a person to alert the supervisor that the process cannot be performed correctly.</p>

<p>This photo from the kitchen of an apartment-hotel is an example of the first type of jidoka - low cost automation eliminating a step of human work. </p>

<p><span class="mt-enclosure mt-enclosure-image" style="display: inline;"><img alt="kitchen karakuri 2.jpg" src="http://www.gembapantarei.com/kitchen%20karakuri%202.jpg" width="348" height="477" class="mt-image-center" style="text-align: center; display: block; margin: 0 auto 20px;" /></span></p>

<p>When the door of the kitchen cupboard is opened, the lid of the trash can is lifted due to tension created in the string attached between the lid and the cabinet wall.</p>

<p><span class="mt-enclosure mt-enclosure-image" style="display: inline;"><img alt="kitchen karakuri 3.jpg" src="http://www.gembapantarei.com/kitchen%20karakuri%203.jpg" width="405" height="358" class="mt-image-center" style="text-align: center; display: block; margin: 0 auto 20px;" /></span></p>

<p>These types of 2-in-1 processes or mechanisms are called nagara in Japanese kaizen circles. The word nagara means "during" or "while doing" something, as in "She sings while she runs". With a bit of creativity we can find motions, data entry tasks or mechanism that can be combined or triggered in such a way to turn manual processes into examples of jidoka - self-working low-cost automation.</p>]]>
        
    </content>
</entry>

<entry>
    <title>Free On-site Lean Diagnostic from Kaizen Institute UK</title>
    <link rel="alternate" type="text/html" href="http://www.gembapantarei.com/2011/11/free_on-site_lean_diagnostic_from_kaizen_institute.html" />
    <link rel="service.edit" type="application/atom+xml" href="http://www.gembapantarei.com/mt-atom.cgi/weblog/blog_id=1/entry_id=5457" title="Free On-site Lean Diagnostic from Kaizen Institute UK" />
    <id>tag:www.gembapantarei.com,2011://1.5457</id>
    
    <published>2011-11-17T04:45:41Z</published>
    <updated>2011-11-17T05:23:25Z</updated>
    
    <summary> Congratulations on the Kaizen Institute UK team for a successful conference and gemba walks with Masaaki Imai in the United Kingdom. In an ongoing effort to spread the word about kaizen and what it can do for organizations, my...</summary>
    <author>
        <name>Jon Miller</name>
        <uri>http://www.kaizen.com</uri>
    </author>
    
        <category term="Kaizen" />
    
    <content type="html" xml:lang="en" xml:base="http://www.gembapantarei.com/">
        <![CDATA[<p><span class="mt-enclosure mt-enclosure-image" style="display: inline;"><img alt="KIUK mapping.jpg" src="http://www.gembapantarei.com/KIUK%20mapping.jpg" width="340" height="255" class="mt-image-center" style="text-align: center; display: block; margin: 0 auto 20px;" /></span></p>

<p>Congratulations on the Kaizen Institute UK team for a successful <a href="http://uk.kaizen.com/contact/kaicho-visit-pictures.html#c16351">conference and gemba walks with Masaaki Imai</a> in the United Kingdom. In an ongoing effort to spread the word about kaizen and what it can do for organizations, my colleagues at Kaizen Institute UK are making a unique offer of a free lean diagnostic, for a limited time.</p>

<p>The Kaizen consultants will not come dressed in <strong>tuxedos</strong>, as amusing as that may be, unless you manage to convince them that this is normal attire on your gemba.</p>

<p>Here is the offer.</p>

<p>-----------------</p>

<p><strong>Free Lean Diagnostic<br />
</strong><br />
During the months of November & December 2011 and January 2012, the Kaizen Institute UK team is offering a select number of free on-site diagnostics of operational excellence. The aim is to help you see opportunities for your company to make improvements in process performance and people development areas, with significant financial, quality or customer service impact. </p>

<p>There are a limited number of days available, <a href="uk@kaizen.com">please contact us</a> to secure your free lean diagnostic.</p>

<p>For a manufacturing organization struggling with production capacity losses, high levels of working capital, poor flow and long lead-times, high error rates or any other factors driving up cost, we can show you benchmarks, identify opportunity areas and recommend next steps.</p>

<p>For a healthcare organization suffering from long patient waiting times, high bed occupancy, patient safety concerns or high stock levels, we would especially like to hear from so we can share practical ways to address these areas.</p>

<p>We have applied our expertise in Kaizen successfully to public sector, retail and a variety of service organizations, and we also invite you to learn how lean can help you. If you would like to take advantage of this offer, please contact us with a brief message to arrange a qualification interview by phone or in person. </p>

<p>The diagnostic will include a formal presentation of findings to your management team, highlighting key areas for improvement. After the diagnostic there is no obligation, sales pressure or commitment to any further engagement with Kaizen Institute.</p>

<p><span class="mt-enclosure mt-enclosure-image" style="display: inline;"><img alt="KIUK client 5S benchmark.jpg" src="http://www.gembapantarei.com/KIUK%20client%205S%20benchmark.jpg" width="340" height="255" class="mt-image-center" style="text-align: center; display: block; margin: 0 auto 20px;" /></span></p>

<p><strong>Contact<br />
</strong><br />
To learn how you can take advantage of the free Lean Diagnostic offered by Kaizen Institute UK, please contact us at:</p>

<p>Kaizen Institute UK<br />
Regus House  <br />
Herald Way <br />
Pegasus Business Park<br />
Castle Donington DE74 2TZ <br />
United Kingdom<br />
Tel: +44 1332 638114<br />
Email: <a href="uk@kaizen.com">uk@kaizen.com</a></p>

<p><span class="mt-enclosure mt-enclosure-image" style="display: inline;"><img alt="Dan Alexander KIUK tux.jpg" src="http://www.gembapantarei.com/Dan%20Alexander%20KIUK%20tux.jpg" width="272" height="346" class="mt-image-none" style="" /></span></p>

<p>I look forward to hearing from you. <br />
Dan Alexander <br />
Managing Director, Kaizen Institute UK </p>

<p>-----------------</p>

<p>Over the past 25 years the Kaizen Institute has been helped hundreds of companies in many different sectors with their Continuous Improvement and training requirements. </p>

<p><a href="http://uk.kaizen.com/consulting.html#c16136">Learn more about</a> the consultancy and training services of Kaizen Institute UK.</p>

<p><span class="mt-enclosure mt-enclosure-image" style="display: inline;"><img alt="KIUK client team.png" src="http://www.gembapantarei.com/KIUK%20client%20team.png" width="340" height="229" class="mt-image-center" style="text-align: center; display: block; margin: 0 auto 20px;" /></span></p>

<p><em>"The Kaizen Institute's team have been extremely effective at getting at "root cause" and driving waste & costs out of the business. They have proved themselves to be especially flexible when we needed support at very short notice" <br />
</em></p>

<p>Site General Manager at a major food manufacturer in the UK</p>]]>
        
    </content>
</entry>

<entry>
    <title>Free Visual Management Webinar - November 17, 2011</title>
    <link rel="alternate" type="text/html" href="http://www.gembapantarei.com/2011/11/free_visual_management_webinar_-_november_17_2011.html" />
    <link rel="service.edit" type="application/atom+xml" href="http://www.gembapantarei.com/mt-atom.cgi/weblog/blog_id=1/entry_id=5452" title="Free Visual Management Webinar - November 17, 2011" />
    <id>tag:www.gembapantarei.com,2011://1.5452</id>
    
    <published>2011-11-10T17:20:42Z</published>
    <updated>2011-11-10T21:02:28Z</updated>
    
    <summary>Next week we will offer our first webinar in collaboration with Gemba Academy. The title of the webinar is &quot;Visual Management: What Good Looks Like&quot; and will provide an overview on how operational excellence in enabled by clear, simple visuals....</summary>
    <author>
        <name>Jon Miller</name>
        <uri>http://www.kaizen.com</uri>
    </author>
    
    <content type="html" xml:lang="en" xml:base="http://www.gembapantarei.com/">
        <![CDATA[<p>Next week we will offer our first webinar in collaboration with Gemba Academy. The title of the webinar is "Visual Management: What Good Looks Like" and will provide an overview on how operational excellence in enabled by clear, simple visuals. Topics will include:</p>

<ol><li>What is visual management?</li>
	<li>Developing problem awareness with visuals in the workplace</li>
	<li>Guidelines for effective visuals</li>
	<li>Examples of visual management from manufacturing and service</li>
	<li>Question & answer</li></ol>

<p><br />
Registration is free. Space is limited to the first 100 people. Join us for a lively and interactive session on <strong>Thursday, November 17, 2011 from 14:00 - 15:00</strong> (GMT - 6, Central Time).</p>

<p><a href="https://www3.gotomeeting.com/register/738551510">Register now--FREE Webinar</a></p>

<p>The webinar will be hosted by Ron Pereira from Gemba Academy and the instructor will be Mike Wroblewski of Kaizen Institute.</p>

<p><span class="mt-enclosure mt-enclosure-image" style="display: inline;"><img alt="wroblewski.png" src="http://www.gembapantarei.com/wroblewski.png" width="91" height="121" class="mt-image-left" style="float: left; margin: 0 20px 20px 0;" /></span></p>

<p>Mike Wroblewski is a Senior Consultant at Kaizen Institute USA with over 25 years of lean transformation experience. Mike's journey into Lean manufacturing began in the 1985 while working for the Hill-Rom Company.  He learned from Shigeo Shingo, successfully reducing die changeover from 45 minutes to less then 5 minutes. Mike has a MS in Manufacturing Management from the GMI Engineering & Management Institute, a BS in Production and Operations Management from Miami University and a Six Sigma Black Belt certification.</p>

<p><a href="https://www3.gotomeeting.com/register/738551510">Register now--FREE Webinar</a></p>]]>
        
    </content>
</entry>

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