Curious Cat Management Improvement Blog: Deming, lean thinking, innovation, customer focus, continual improvement, six sigma.
August 31, 2006

Permanent Innovation

Langdon Morris has written a new book: Permanent Innovation. There is a blog and web site too. The book builds upon his article, Business Model Warfare:

Furthermore, the core of the innovation value proposition need not be built around a technology per se. In the examples cited above - Toyota, Honda, Nissan, Nike, Visa, Dell, Fedex, Home Depot, Southwest Airlines, and Ford (in the early days) - proprietary technologies play a part in the company’s success, but there is always much more. The key to success is a focus not on technology itself, but technology applied in a business process to optimize the relationship between the company and its customers. In today’s environment nearly any technology can be, has been, and will be copied, so the important competitive advantage is knowing how to use technology in a way that adds the greatest value for customers.

Complicating Simplicity

Complicating simplicity:

Gah! Trying to read about the “Simplicity: The Art of Complexity” (er, what?) conference. But the description at the conference site is the exact opposite of simple, clear writing:

An investigation of the essence of simplicity must necessarily get involved with the psychology of human-machine interaction. Why do we display such a strong proclivity to regarding technology as an externally imposed authority, to condemning or venerating it?…If we merely equate simplicity with simplification and reduction, simply let the technology become “invisible”, we not only manifest our inability to even recognize the type and extent of the technological deployment

This post on the excellent signal vs. noise blog illustrates how one can lose their way when trying to simplify. Lean and other management improvement folks can learn a lot about eliminate non-value added steps, clean design, simplifying systems to improve performance… from this blog. The examples are mainly relating to software development from a true understanding of lean thinking (though I don’t have any evidence they are familiar with the Toyota Production System or lean tools/concepts).
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Graban Interviews Liker

Another excellent podcast from the Lean Blog: Dr. Jeffrey Liker.

Dr. Liker discusses the subtleties of doing actually doing lean versus talking about doing lean. Dr. Liker has authored: The Toyota Way, The Toyota Way Fieldbook and The Toyota Product Development System: Integrating People, Process And Technology. His consulting firm is: Optiprise.

True lean management is not instant pudding. The more knowledgeable people are about lean practices the less they focus on quick fixes and the more they talk about deep changes. And yet some quick gains are possible. The challenge is to use early gains to build the capacity of the organization for the truly remarkable possible long term gains.

August 30, 2006

Toyota Targets 50% Reduction in Maintenance Waste

Inside the Toyota Maintenance Reduction 50 Percent by Paul V. Arnold:

First, it is Maintenance Reduction 50 Percent, not Cost Reduction 50 Percent or Employee Reduction 50 Percent.

“The goal is to reduce maintenance activities and the maintenance that you perform on a machine by 50 percent. That goal covers every machine and every activity,” says TMMK facilities control manager David Absher.

This is not about arbitrarily chopping budgets or personnel. It’s a game plan that balances today’s corporate wants and needs with long-term implications and vision.

I think this is another example of how potentially dangerous targets or goals can be used within a excellent management system effectively. Still such target can be dangerous, even in an excellent management system - so it is a tool to be used with great care (especially when the management system does not embody many principles of management improvement). (more…)

August 29, 2006

Senge and Deming

Jeff Sutherland quoting Dr. Deming’s response to Peter Senge request for a comment on his book, The Fifth Discipline:

“Our prevailing system of management has destroyed our people. People are born with intrinsic motivation, self-respect, dignity, curiosity to learn, joy in learning. The forces of destruction begin with
toddlers—a prize for the best halloween costume, grades in school, gold stars—and on up through the university. On the job, people, teams, and divisions are ranked, rewarded for the top, punished for the bottom. Management by Objectives, quotas, incentive pay, business plans, put together separately, division by division, cause further
loss, unknown and unknowable.”

See page 125 of New Economics, by W. Edwards Deming on the Forces of Destruction.

Related: Deming on Management - unknown and unknowable figures - Dangers of Extrinsic Motivation - Problems with Bonuses - Failed Personnel Practice: Forced Ranking

August 28, 2006

Lean Leaders

Lean leaders by April Terreri:

Tim Corcoran, vice president of ZF Sales & Services, NA, LLC, that re-manufactures automotive transmissions and steering systems in Vernon Hills, IL. “We had a number of false starts by implementing tools like kaizen, value stream mapping and the 5Ss,” he admits. “We found it’s really about the thinking and how we approach work.” Once he and his first-line managers participated in a lean workshop at Lean Learning Center, everything began to click. “We learned to identify problems, analyze them and develop processes to solve them the same way every time.”

The tools are very helpful but the change in mindset is critical. Without the change in the way business is viewed the tools may be able to help but often can prove of limited value. Once an organization starts truly adopting principles like surfacing problems so the system can be fixed instead of hiding problems so the individual doesn’t get blamed then the tools are critical to provide results that will encourage those who are skeptical to at least try this new way of looking at things.

Smith discovered some workers were hiding scrap. “They were afraid; but I told them the only thing I care about is how to prevent it from happening again,” he says. Scrap has since dropped dramatically–about 50 percent over the last few years.

Exactly!

August 27, 2006

Wisconsin Manufacturing

Editorial: A way forward for state companies, Milwaukee Journal Sentinel

The idea of lean manufacturing is pretty close to a religion at Ariens these days. The tenets: Be quick on the draw. Improve continuously. Be open to change. Get everyone - shop floor to board room - involved. The company’s output has nearly tripled in six years with a work force that has remained steady at about 1,000. Productivity is up, on average, about 17% a year, Ariens says.

Manufacturing and related industries are still a huge piece of Wisconsin’s economy - nearly half by some estimates.

The state should boost funding for the Wisconsin Manufacturing Extension Partnership, which preaches the gospel of lean manufacturing. Statewide, companies helped by the partnership reported $233 million in improvements during fiscal 2006. The non-profit group offers low-cost consulting to small- to mid-sized companies and receives both state and federal funding.

It’s a sign that Wisconsin manufacturers can play a major role in the state for years to come. And lean manufacturing is a key to that.

Wisconsin continues to succeed as an example of manufacturing success. (more…)

August 26, 2006

Intellectual Property Rights and Innovation

How intellectual property influences innovation and growth in the economy depends on the application of intellectual property law. No intellectual property (IP) rights would hinder innovation. Complicated application of confusing and overreaching IP rights also hinders innovation. Now I see the USA systems as having overreaching claims of IP rights, IP rights granted for obvious ideas which then are used to extort those actually producing value and overall a system much in need of improvement.

Lawrence Lessig does the best job of presenting the value of improving our application of IP law.

Related: The Patent System Needs to be Significantly Improved - Patent Review Innovation - Is the US Patent System Endangering American Innovation? - Do Intellectual Property Rights Help or Hinder Innovation? by Amy Rowell

August 25, 2006

Cyberpunk Manufacturing

Raising the Floor by Alex Soojung-Kim Pang:

The transformation of the factory from a vast machine into a creative, knowledge-intensive space is a development few could have seen. Are you ready for the next industrial revolution?

So what will the factory of the future be like? It will be aware of how users are reacting to both its latest products and still-under-NDA prototypes, feeding off streams of information coming in from prototypes, recycled units, market-watching software agents, and blogs and discussion boards. It will be able to shift production lines in a matter of days or hours, and will constantly incorporate the latest insights from the lab and the natural world. The combined effects of cascades of information and pressure for constant innovation will turn the factory floor from a space populated only by machine-tenders, into a space in which production and innovation happen simultaneously.

Sounds like lean manufacturing. The author mentioned six sigma and TQM but not lean. The article is a bit over the top, but does illustrate how cultural trends add to the benefits of a lean future.

Defined: NDA - non disclosure agreement. More management definitions.

August 24, 2006

Making Changes and Taking Risks

Sales Force by Curtis Hartman, 1996 explores Ron Rodin’s use of Deming’s ideas at Marshall Industries. Ron Rodin’s boo, Free Perfect and Now, is excellent.

The system had to change. “We eliminated commissions, incentives, promotions, contests, P&Ls, forecasts, budgets, the entire functional organization chart,” Rodin says. It was a radical move. Contests and commissions — internal competition — were a way of life in the industry, the universal motivational tool. Rodin was hammered when he unveiled the plan in an open letter to the industry. One competitor accused him “of kissing Deming’s ring.” Another called the system “communistic.” Electronic Buyers News, the industry bible, published a biting editorial.

Yes the article is 10 years old by as I have stated numerous times I don’t believe only things written in the last week have value. Going back to the great stuff (even if you have read it before) is often much better than reading whatever is new.

August 23, 2006

Internet Access at Work

Providing internet access at work can create some management issues. However, the correct solution to those problems is not to be overly restrictive on access to the internet.

Obviously, the most important thing is doing the work of the organization: there is no excuse for employees ignoring customers or pressing needs to IM with their friends or browse the web. However, if you hire responsible people and manage properly - maintaining a proper work culture, etc., you should respect and trust your employees.

Internet access does create the potential for abuse. And I think it may well require more management involvement to assure it is not abused (because the temptation is so great) but much of that management involvement is probably a good thing. Management, in general, is too far removed from what is actually going on (see Dilbert’s pointy haired boss).
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August 22, 2006

Toyota Land

Toyota electric cars in Toyota City

A visit to Toyota City: In Toyota land by Vinod Jacob:

When I was a little boy it was fascinating to read about Toyota’s vision for non-polluting vehicles to replace existing versions. I used to marvel at the sketches of the futuristic small vehicles plying inside the Toyota campus. A visit to the Toyota headquarters proved this to be a reality. Just outside the Toyota technical centre are the E-com vehicles put on a charger.

Visitors are welcomed by robots playing the clarinet.

The `Toyota way’ is explained through audio-video shows that cover concepts such as JIT (just-in-time manufacturing system), Kanban cards, andon cords, synchronising dolly for instruments, and raku-raku flexible seats.

Toyota City website with info and web videos

Another article by Vinod Jacob - Ford centenary: A legacy revisited

via: Lean Blog

Danaher Practicing Lean Thinking

Manufacturer’s Acquisition Strategy Sets It Apart From The Pack, Investors Business Daily:

“It’s adapted from the Japanese Kaizen system,” Holmstead said. “Kaizen is a way of removing waste and standardizing processes and bringing underperforming or slow-growth companies with maybe single-digit margins up to midteen margins.”

The keys are standardization, measurement and innovation — all directed toward the goal of continuous improvement.

“It’s basically a set of tools that allows Danaher to make whatever widget they are manufacturing at a cost less than most of their competitors,” said Morningstar analyst Eric Landry. “Over the past decade they have (also been moving) DBS into the back office and into sales. It produces a culture where you are never satisfied.”

The quotes are from Wall Street Analysts. I think basically they like the ever increasing cash flow and then use the story the company gives for why they are successful. Still they are playing up lean thinking.
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August 21, 2006

Gladwell (and Drucker) on Pensions

The Risk Pool by Malcolm Gladwell (author of The Tipping Point and Blink):

The most influential management theorist of the twentieth century was Peter Drucker, who, in 1950, wrote an extraordinarily prescient article for Harper’s entitled “The Mirage of Pensions.” It ought to be reprinted for every steelworker, airline mechanic, and autoworker who is worried about his retirement. Drucker simply couldn’t see how the pension plans on the table at companies like G.M. could ever work. “For such a plan to give real security, the financial strength of the company and its economic success must be reasonably secure for the next forty years,” Drucker wrote. “But is there any one company or any one industry whose future can be predicted with certainty for even ten years ahead?” He concluded, “The recent pension plans thus offer no more security against the big bad wolf of old age than the little piggy’s house of straw.”

Pension plans did work well for a short period of time. But recently they (along with the attached retiree health care) are one of the big problems facing large old companies: like GM. Gladwell talks about the dependency ratio for an economy and the dependency ratio of companies. Worsening dependency ratios can cause pension plans to kill companies (if they are not funded when the obligation is incurred) - as the company is forced to pay for more and more retirees with fewer and fewer workers.
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August 20, 2006

Toyota’s New Texas Plant

Toyota exec stands up to Texas heat by Cheryl Hall:

Toyota’s new Texas plant is coming on line and will further increase Toyota’s contribution to the US economy, by buying from local suppliers and most importantly by working with local suppliers:

And he’s well-acquainted with those 21 on-site suppliers, which Toyota refers to as equal partners and a vital component in this ahead-of-the-industry endeavor.

Each of the 200,000 trucks produced annually will have up to 30,000 parts that are mostly made in surrounding buildings. Without on-site production, parts would travel up to 2,000 miles to San Antonio. A lot of things can happen to them during such a long haul. And those 18-wheelers produce emissions by the cloud-load – a key concern for Toyota, says Mr. Tajima.

“We really believe that the true meaning for our company’s existence is better quality, better performance, better reliability and being kinder to Earth, which means fuel efficiency and lower pollution, not only with the product but in the process of making it,” he says. “Otherwise, we’re just like everyone else.”

Previous post on Toyota’s supplier development. The article includes some interesting information on how Toyota has been hiring, they:
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Ackoff, Idealized Design and Bell Labs

Excerpt from Idealized Design: How to Dissolve Tomorrow’s Crisis…Today by Russell L. Ackoff, Jason Magidson and Herbert J. Addison: How Bell Labs Imagined — and Created — the Telephone System of the Future in the 1950s.

Great stuff and another example showing the obsession with “new” ideas is wasteful.

Idealized design is a way of thinking about change that is deceptively simple to state: In solving problems of virtually any kind, the way to get the best outcome is to imagine what the ideal solution would be and then work backward to where you are today. This ensures that you do not erect imaginary obstacles before you even know what the ideal is.

A simple idea, and a powerful one too. Ackoff always presents his ideas very well, in this book, and in many articles by Dr. Ackoff available online. I still remember Dr. Ackoff’s presenting this material at a Hunter conference years ago - great stuff.
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August 19, 2006

Distort the System

From our post: Targets Distorting the System, Dr. Brian Joiner:

spoke of 3 ways to improve the figures: distort the data, distort the system and improve the system. Improving the system is the most difficult.

Another example of this in practice: Recount helps one university rise in the rankings:

Behnke, who says he’s no fan of rankings, said he recently spoke to a provost at another institution who was capping class sizes at 19 to boost the “Classes Under 20″ number.

I am sure “classes under 20″ is a proxy for an intimate learning environment and interaction with knowledgeable professors that can teach well. You can’t directly measure the benefit of interaction with a professor in a small group on learning to create data to be used in ranking schools (Deming on unknown and unknowable figures). So classes with under 20 students and % of faculty with PhDs… are used as proxies for this idea.
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August 18, 2006

Improving the 401(k) System

401(k)s are a great retirement investment vehicle (for those in the USA). Since the introduction of 401(k)s they have proved very advantageous to those saving for their retirement. See our previous post on: Saving for Retirement.

However, the experience thusfar shows a weaknesses in the system. Many people don’t even take advantage of a 401(k) to save for their retirement. From a public policy perspective it creates a huge long term problem. The economy will end up with millions of people that didn’t save for retirement and will be a drain on those who did save for retirement and the rest of the economy.

So Congress actually passed a good revision to the law. Employers will now be required to default to having employees save for their retirement in 401(k) plans. The employee still has the option to decline doing so, but now, without such a choice, they will automatically save for retirement. Great news, if like me, you believe many who would have not saved for retirement now will, and that doing so will be a good move for them and for the overall economy.

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