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Lean thinking, lean manufacturing, Toyota Production System management and manufacturing thinking. See our lean management portal, inlcuding lean articles (articles by Jim Womack) and online resource.
Terms: continuous flow - kaizen, jidoka, JIT, muda, mistake proofing, takt time, more
Recommended posts: Respect for People - Lean Thinking and Management - The Lion of Lean - Visible Data - Bad Management Results in Layoffs


Deming Seminar in Singapore: New Philosophy of Management

image of the Deming medal

The W. Edwards Deming Institute is working with the NTUC LearningHub to offer management seminars in Singapore. I will be co-facilitating at several seminars in Singapore with Kelly Allan and Kevin Cahill next month.

The 2 1/2 day Seminar, Deming’s New Philosophy of Management, is open for registration to the public so if you want to join us, sign up for the seminar which will be held January 18 to 20, 2011 in Singapore.

In the seminar you will learn the way of thinking taught by Dr. W. Edwards Deming. Those ideas have been used by leading companies around the world and the value of these management ideas is as high today as it has ever been. Applying these ideas will allow your organization to achieve higher quality, lower costs and increased productivity. As regular readers of this blog know I often write about these ideas here.

Seminar Overview
Application of Dr. Deming’s “New Philosophy of Management” gives you the insight to remove barriers to success, increase efficiencies, reduce waste, boost motivation, stimulate innovation and understand your organization and its real capabilities. Some improvements are as simple as stopping current practices and enjoying productivity increases. Others require learning and understanding the four key components of the “New Philosophy of Management:”

The seminar is conducted with facilitators. It is not lecture style and is interactive and significant time is spent in exercises or discussions and their application. The seminar is based on Dr. Deming’s two books on management – Out of the Crisis and The New Economics. It focuses on a philosophy of four components that lead to understanding of how the organization can work as a system, how an organization can learn as it develops, how to get the best out of people, and interpret data.

After the seminar you will have an understanding of the four critical elements of Deming’s “New Philosophy of Management” and how to apply it within your organization. They are:

Who Should Attend
The seminar material is applicable to senior executives and management in every size of business and service organization, education, retail, health care, government and manufacturing. It will benefit those being introduced to Deming’s thinking for the first time as well as those familiar with his philosophy.

The Achilles’ Heel of Agile

Guest post by Jurgen Appelo

When I wrote this, I was working in a big open office space in the Van Nelle Factory in Rotterdam (see photo). About 100 people work in an office that was the first of its kind in Europe, when it was built in 1929. And more than 80 years later, architecture lovers from all over the world still come to admire it, take pictures, and make drawings. I sometimes waved at them.

photo of open office style at Van Nelle Office
Van Nelle office, reprinted by permission of Stephan Meijer

A big open office space has advantages and disadvantages. Advantages are flexibility and easy communication. The main disadvantage is that it is a shared resource for all who work there. Climate, sound, and light are hard to manage in a space like that, and the optimal configuration for the whole is never optimal for all. But our office manager did the best she could in trying to maximize pleasant working conditions, while maintaining tight rules to keep things under control. A shared open office is not the ideal environment to give people full responsibility over their own working space.

Self-organization is usually promoted in agile software development. But when shared resources are not managed by a central authority, self-organization often results in the Tragedy of the Commons. The name refers to a situation in which multiple self-organizing systems, all acting in their own self-interest, overexploit a shared limited resource, even when they all know it is not in anyone’s interest for this to happen. The impact that humanity has on CO2 levels in the air, trees in the forests, and fish in the sea, is right now the most debated and intensively researched case of the Tragedy of the Commons. Organizations also have shared resources, like budgets, office space, and system administrators. We could see them as the business-equivalent of the air we breathe, the landscape we change, and the fish we eat.

Research indicates that four ingredients (called the four I’s) are needed for sustainability of shared resources [Van Vugt 2009:42]:

  • Institutions [managers] who work on building trusting relationships between competing systems [teams] in order to increase acceptance of common rules;
  • Information that increases understanding of the physical and social environment, in order to reduce uncertainty (because uncertainty results in bias towards self-interest);
  • Identity, or a need for a social “belonging” that encompasses all participants, to improve and broaden one’s sense of community and reduce competition between teams;
  • Incentives that address the need to improve oneself, while punishing overuse and rewarding responsible use.

Research shows that it is imperative that there is some form of management (or governance) to protect these shared resources by working on these four I’s. (I realize that most modern day governments are not setting a good example of how to do that.) In the case of shared resources, whether it concerns money, space, or system administrators, someone outside of the development teams must keep an eye on long-term sustainability instead of short-term gains by individual teams.

The Tragedy of the Commons is the Achilles’ heel of Agile. It takes management to protect that heel, in order to prevent teams from depleting resources, and crippling the organization.

This article is an adaptation from Management 3.0: Leading Agile Developers, Developing Agile Leaders, by Jurgen Appelo. The book will be published by Addison-Wesley, in Mike Cohn’s Signature Series.

Related: Embrace Diversity, Erase Uniformitymanagement 3.0agile software development booksVW Phaeton assembly plant

Management Improvement Carnival #118

Mike Wroblewski is hosting the Management Improvement Carnival #118 on the Got Boondoggle? blog, highlights include:

  • Voice of Customer (VOC): What does it mean? By Mark Wheeler – “Most companies have some type of VOC program in place. Many programs fall short of delivering measurable value. This failure often lies at the definition level of VOC. But how do you actually define it?”
  • He Should Have Seen It by Mark Rosenthal – “We talk about 5S, separating the necessary from the unnecessary, a lot, but usually apply it to things. What about information?” (Also read the link in this post!)
  • Going to Gemba with Grandma by John Wetzel- “I saw something that I would never have discovered if I hadn’t gone to the gemba.”

Related: Management Improvement Carnival #97Management Improvement Carnival #82Management and Leadership Quotes

How to Get a New Management Strategy, Tool or Concept Adopted

Often when learning about Deming’s ideas on management, lean manufacturing, design of experiments, PDSA… people become excited. They discover new ideas that show great promise to alleviate the troubles they have in their workplace and lead them to better results. But how to actually get their organization to adopt the ideas often confounds them. In fact, I believe most potential improvements efforts may well fail even before they start because people can’t get past this problem.

I believe the way to encourage adoption of management improvement tools, methods and ideas is to solve people’s problems (or give them new opportunities). Instead of trying to convince people by talking about why they need to adopt some new ideas, I think it is much better to show them. To encourage the adoption of whatever it is (a philosophy like Deming or a new tool) try to find projects that would be good candidates for visible success. And then build on those successes.

For adopting whole new ways of working (like lean thinking) you go through this process many times, adding more and more new ideas to the accepted way of doing things. It is a bit easier if you are the CEO, but I think the strategy is very similar whoever you are. For smaller efforts a boss can often just mandate it. But for something like a large improvement in the way work is done (adopting a lean management system, for example), the challenge is the same. You have to convince people that the new methods and ideas are valuable and that they can use the ideas to help improve results.

Start small, it is very helpful if initial efforts are fairly small and straight forward. You often will have limited resources (and limited time people are willing to invest) at first. so start by picking projects that can be accomplished easily and once people have seen success more resources (including what is normally the most important one – people’s time) should be available. Though, honestly getting people to commit will likely be a challenge for a long time.

It is a rare organization that adopts a continual improvement, long term focus, system thinking mindset initially. The tendency is often strong to focus on fire fighting, fear (am I taking a risk by doing x, if I spend time improving y – what about the monthly target my boss is measuring me on…) and maintaining the status quo. It is baffling to many hoping for improvement, when you have huge successes, and yet the old way of doing things retains a great hold. The inertia of organizations is huge.
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Management Improvement Carnival #117

Bryan Lund is hosting the Management Improvement Carnival #117 on the Training Within Industry blog, highlights include:

  • Mark Hamel at Gembatales warns us against the danger of serving two masters…I love the caricatures that he develops for the reader – spot on!
  • A great take on muda, muri and mura by David Kasprzak at My Flexible Pencil. The way David applies the 3Ms to cultural behaviors is clever and thought provoking. Although seemingly “intangible” at first, the cultural wastes that David describes here soon emerge as the first logical target for attack, thereby allowing individuals in the organization to focus on building the ideal relationships so desperately needed to perform at the highest potential.
  • Kevin makes the case for single piece shopping at Evolving Excellence, but not everyone is biting in the comments section…me, I’m on the fence on this. JIT for purchasing makes sense for many, many things but probably shouldn’t be applied blindly to all purchases…

Related: Management Improvement Carnival #952010 Management Review Carnival

No True Lean Thinking or Agile Software Development

“There is no true value of any characteristic, state, or condition that is defined in terms of measurement or observation.” – Dr. W. Edwards Deming.

The value depends on your operational definition.

Once you operationalize management ideas in a real organization it necessarily should have differences from how it is operationalized elsewhere. As Deming said there are no effective simple recipes for management. It is one of the frustrations people have with Dr. Deming: that there is no cookbook telling you what you should go do as a manager. You need to understand things like: interactions, variation, psychology, systems thinking, how we know what we know (and what we “know” that isn’t so). And then you need to make decisions about how to apply these concepts in your organization.

There is value in being able to think and discuss ideas in a broader context than your organization. You lose a great deal of learning opportunities if you can’t. And having common idea about what common principles a lean thinking organization or agile software organization should have is helpful I believe. That is aided by abstract ideals of these management practices.

Dilbert comic on the futility of process and arbitrary deadlines

One of agile’s guiding principles is individuals and interactions over processes and tools. I am a Deming follower and that emphasizes the importance of process and system. The words in agile are anti-process. But in my experience it is really a specific type of process – and that is basically idiotic adherence to process that the software developers are sick of. This attitude is best summed up in Dilbert. There are plenty of what I would call process in the practice of agile – sprints, kanban, work in process limits, define what done means, using user stories, retrospectives, build in quality… Basically I think it is important to understand what the principles mean, but don’t get locked into dogmatic ideas.

There are principles that seem to me necessary to, for example, consider an effort as lean management. There must be respect for people in lean management. If it isn’t there, then I don’t think it is lean. It might be management using some ideas and tools from lean, but it isn’t lean management. Exactly how respect for people is manifest is up to the organization. The same thing holds for other principles.

Thoughts on No True Agile, No True Lean, No True Latte

Related: Dr. Deming: There is No True ValueHow to Manage What You Can’t MeasureInvolve IT Staff in Business Process ImprovementThe Illusion of Knowledge

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Airport Security with Lean Management Principles

The ‘Israelification’ of airports: High security, little bother

We [Israel] said, ‘We’re not going to do this. You’re going to find a way that will take care of security without touching the efficiency of the airport.”

“The whole time, they are looking into your eyes — which is very embarrassing. But this is one of the ways they figure out if you are suspicious or not. It takes 20, 25 seconds,” said Sela. Lines are staggered. People are not allowed to bunch up into inviting targets for a bomber who has gotten this far.

Lean thinking: customer focus, value stream (don’t take actions that destroy the value stream to supposedly meet some other goal), respect for people [this is a much deeper concept than treat employees with respect], evidence based decision making (do what works – “look into your eyes”), invest in your people (Israel’s solution requires people that are good at their job and committed to doing a good job – frankly it requires engaged managers which is another thing missing from our system).

The USA solution if something suspicious is found in bag screening? Evacuate the entire airport terminal. Very poor design (it is hard to over-emphasis how poor this is). It will take time to design fixes into physical space, as it always does in lean thinking. It has been nearly 10 years. Where is the progress?

The Colbert Report Mon – Thurs 11:30pm / 10:30c
Tip/Wag – TSA, Bert & Dogs<a>
www.colbertnation.com
Colbert Report Full Episodes 2010 Election March to Keep Fear Alive
A screener at Ben-Gurion has a pair of better options. First, the screening area is surrounded by contoured, blast-proof glass that can contain the detonation of up to 100 kilos of plastic explosive. Only the few dozen people within the screening area need be removed, and only to a point a few metres away.

Second, all the screening areas contain ‘bomb boxes’. If a screener spots a suspect bag, he/she is trained to pick it up and place it in the box, which is blast proof. A bomb squad arrives shortly and wheels the box away for further investigation.

This is a very small simple example of how we can simply stop a problem that would cripple one of your airports,” Sela said.

Lean thinking: design the workspace to the task at hand. Obviously done in one place and not the other. Also it shows the thought behind designing solutions that do not destroy the value stream unlike the approach taken in the USA. And the better solution puts a design in place that gives primacy to safety: the supposed reason for all the effort.
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Good Process Improvement Practices

Good process improvement practices include:

  • standardized improvement process (pdsa, or whatever)
  • Going to the gemba – improvement is done where the work is done. You must go to the where the action is. Sitting in meeting rooms, or offices, reading reports and making decisions is not the way to improve effectively.
  • evidence based decision making, data guides decision making rather than HiPPO
  • broad participation (those working on the process should be the ones working on improving it and everyone in the organization should be improving their processes)
  • measurable results that are used to measure effectiveness
  • pilot improvement on a small scale, after results are shown to be improvements deploy standardized solutions more broadly
  • visual management
  • Standardized work instructions are used for processes
  • one of the aims of the improvement process should be improving peoples ability to improve over the long term (one outcome of the process should be a better process another should be that people learned and can apply what they learned in future improvements)
  • quality tools should be used, people should be trained on such tools. The tools are essentially standardized methods that have been shown to be effective. And most organization just ignore them and struggle to reinvent methods to achieve results instead of just applying methods already shown to be very effective.
  • the improvements are sustained. Changes are made to the system and they are adopted: this seems obvious but far too often process improvements are really just band-aids that fall off a few weeks later and nothing is done to sustain it.
  • goals, bonuses and extrinsic motivation are not part of the process
  • The improvement process itself should be continually improved

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Management Improvement Internal Experts

Having a group of internal experts in Deming, lean thinking, six sigma, etc. can be an good way to help the organization transform but they must 1) practice respect for people and 2) focus on building organizational capacity. Having, for example a few experts that are very focused on lean thinking and can be tapped by others in the organization I think can be very useful.

That group might well also serve as “change agents” which can make some people get mad at them. They can help push the organization to change. While it might be nice to think you can just show the wonderfulness that is lean thinking and everyone will immediately drop all their old habits and embrace lean thinking that often doesn’t happen. You might well have to push middle mangers (and others) outside their comfort zone. And you might well have to push people to really try this stuff and they have become so disheartened over the years by promises of new, better, ways to work. They just see this as one more lame pointy haired boss attempt and they may well not want to play.

A big focus should be on making improvement in the performance of the organization, obviously, but also on making it clear that this new way of doing things is helpful and will make it a better place to work. The role of internal management improvements efforts is to build the capacity of the rest of the organization to improve. Six sigma efforts often instead put the emphasis on six sigma experts doing the improvement instead of coaching and providing assistance to those who best know the processes to improve, which I see as a mistake.

Response to The “Lean Group” Syndrome
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Respect People: Trust Them to Use good Judgment

Nordstrom’s employee handbook used to be presented on a single 5 x 8 card:

Welcome to Nordstrom
We’re glad to have you with our Company. Our number one goal is to provide outstanding customer service. Set both your personal and professional goals high. We have great confidence in your ability to achieve them. So our employee handbook is very simple.

We have only one rule: Use good judgment in all situations.

Please feel free to ask your department manager, store manager, or division general manager any question at any time.

That is no longer the case, however, as they have become more like everyone else. Simple ideas like this only work within the right context. Taking such ideas and applying them to an organization that isn’t ready will backfire. But if you build a culture where trust, respect, customer service and responsibility are encouraged lots of rules just get in the way of people doing their best. If you can’t trust employees to do their jobs, the problem is with the system you have that results in that, not the people you can’t trust.

Related: Trust Employees to Do What is RightHire People You Can Trust to Do Their JobWe are ladies and gentlemen serving ladies and gentlemenFlaws in Understanding Psychology Lead to Flawed ManagementBuild an Environment Where Intrinsic Motivation Flourishes

The role of leadership in software development

The webcast of Mary Poppendieck’s talk, The role of leadership in software development, at Google. As usual Mary does a very nice job of providing some good historical background while exploring wise management practices (tied to software development but plenty useful for any manager).

via: Sheep of a different fold

Related: Lean, Toyota and Deming for Software DevelopmentWebcast on the Toyota Development ProcessDon’t Use Performance AppraisalsLean Software DevelopmentThe Leader’s Handbook

Lean Daily

Lean Daily iPhone app

Lean Daily consolidates the latest posts from seven excellent lean blogs in one convenient, free, iPhone app. Learn more about it, see a simulator demo, and download it directly from iTunes.

Mark Graban, Lean Blog, took the lead and a number of us combined efforts to provide this as a free service to our loyal readers:

This iPhone app allows you to read these lean blogs while on the go. You can also listen to and view some multimedia lean content, such as the Lean Blog Podcasts and Video Podcasts and the Gemba Academy sample videos in the app as well. You can also find lean news and some other feeds.

Related: Curious Cat management blog directoryInteresting management content (Reddit)search for management content online



Finding Great Management Articles, Posts and Resources

Reddit is a web site that ranks web pages by user votes. The site uses an algorithm that has a very large timeliness factor. So top ranked links move down the list fairly quickly. This results in a nice site to look at to find links others have found interesting recently.

I created a management sub-reddit (a distinct topic-focused-area on the management improvement topics covered in this blog) in 2008. The sub-reddit seems to be about ready to reach a critical mass, so I am making a push to get those interested in management and specifically Deming, lean management, agile software development, six sigma and the things I normally write about on this blog to participate.

If you sign up you can not only vote on the links displayed but add new links (that then will be voted on by others). I think Reddit does a very good job of using social aspects of the internet to provide recommendations that are worthwhile (I have used the site for years).

The management subreddit depends on the community of users to voice their opinions. And I have an interest in having the community form around the management ideas I value (see my other blog posts for what that is). So I encourage you to give it a try and vote on links you enjoy and add new articles, web sites, blog posts… The benefit of this subreddit will grow as we grow the number of participants and if it develops a shared culture of value.

Related: Creating the Management Sub-Reddit (2008)John Hunter’s social site links (Reddit, Kiva, LinkedIn)Dell, Reddit and Customer FocusCurious Cat Management Improvement LibraryManagement Improvement Blog Carnival

The Toyota Way – Two Pillars

Toyota is receiving plenty of criticism now, much of it for good reason. There is also a large amount of psychology involved. From what I have seen, the insurance companies still see better claims history (fewer and lower cost claims) against Toyota than other manufacturers. And there is another strain that seems to enjoy criticizing what has been praised. Toyota does need to improve. But that is improvement of the existing management system, not a need to radically change the management of the company.

I think Toyota, even with the problems, is a fantastic example of a very well managed company. Yet even with all the study of lean manufacturing even basic ideas are overlooked. For example, the two main pillars of the Toyota way are “continuous improvement” and “respect for people.” For all of us, it is valuable to refocusing on core principles. We are too often looking for the next new idea.

This is one way of looking at the pillars of the Toyota Production System, from the Toyota Technical Center – Austrailia

Image of Toyota's pillars of management: respect for people and continuous improvement

Continuous Improvement means that we never perceive current success as our final achievement. We are never satisfied with where we are and always improve our business by putting forth our best ideas and efforts: we are keen to create better alternatives, question our accomplishments and investigate future definitions of success.

There are three building blocks shaping our commitment to Continuous Improvement:

1. Challenge – we form a long term vision, meeting challenges with courage and creativity to realize our dreams;
2. Kaizen – we improve our business operations continuously, always driving for innovation and evolution
3. Genchi Genbutsu – we go to the source to find the facts to make correct decisions, build consensus and achieve goals.

Respect For People refers to our own staff as well as the communities and stakeholder groups that surround us and we are part of. We respect our people and believe the success of our business is created by individual efforts and good teamwork.

Respect For People is translated in:

1. Respect – we respect others, make every effort to understand each other, take responsibility and do our best to build mutual trust
2. Teamwork – we stimulate personal and professional growth, share the opportunities of development and maximize individual and team performance.

These elements combined define our corporate DNA, provide a way of operating that is recognised by each and every Toyota-member around the globe and enables us to sustain our success in the future.

Back to Basics for Toyota by Akio Toyoda

When my grandfather brought Toyota into the auto business in 1937, he created a set of principles that has always guided how we operate. We call it the Toyota Way, and its pillars are “respect for people” and “continuous improvement.” I believe in these core principles. And I am convinced that the only way for Toyota to emerge stronger from this experience is to adhere more closely to them.

While recent events show Toyota obviously needs to improve, that has been true all along (it is just more obvious lately). Some may see this as an indication that these lean manufacturing ideas based on Toyota’s practices are no better than other management practices. I don’t believe this. I feel just as strongly about the value of lean management as ever. I think that the recent events show you that no matter how well an organization in managed there is plenty of room to improve. Toyota never was close to perfection. They have much to improve, but they are still one of the best managed companies in the world.

My comments in 2005:

I think the instances of such failures are just a sign that even Toyota still has quite a bit to improve. I think this announcement likely is a result of common cause variation (it is the natural result of the current system). The natural result (of the system) is not that they have this particular failure, but that this recall is consistent with the % of vehicles that required a recall of this general character. I believe they are getting better over time but they still have a long way to go. With a result based on common cause you want to look at the entire system when designing an improvement plan not at the root cause of the seat belt issue. See Responding to Variation online and the book, Forth Generation Management, by Brian Joiner.

Related: Toyota Stops Lines – Lots of LinesAkio Toyoda’s Message Shows Real LeadershipDeming CompaniesRespect for People Does Not Mean No Criticism

And my comments in 2007:

I don’t agree that they need to rethink their purpose in life (I have a feeling that is taken out of context). They need to maintain and maybe even increase their commitment to their purpose in life.

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Toyota’s Journey to Lean Software Development

Toyota’s journey from Waterfall to Lean software development by Henrik Kniberg

Toyota builds cars (duh). In the past that didn’t involve much software, and the little software that was needed was mostly developed by suppliers and embedded in isolated components. Toyota assembled them and didn’t much care about the software inside. But “The importance of automatic electronic control system has been increasing dramatically year by year” said Ishii-san.

A modern car is pretty much a computer on wheels! In a hybrid car about half of the development cost is software, it contains millions of lines of code as all the different subsystems have to integrate with each other. He mentioned that a Lexus contains 14 million lines of code, comparable to banking and airplane software systems. Ishi-san concluded that “Therefore Toyota needs to become an IT company”.

Most of Toyota’s ideas about how to do Lean software development resonated well with me. My feeling was that they are on the right track.

One thing bothered me though – the extreme focus on detailed metrics. I agree with the value of visualization, standardization, and data-driven process improvement – but only if used at a high level. My feeling was that Toyota was going to far. They say engineer motivation is critical, but how motivating is it to work in an organization that plans and measures everything you do – every line of code, every hour, every defect, how many minutes it takes to do an estimate, etc?

via: Justin Hunter

Related: Toyota IT OverviewToyota Canada CIO on Genchi Genbutsu and KaizenLean Software DevelopmentMy First Trip to Japan by Peter ScholtesToyota IT for Kaizen

Improving Software Development with Automated Tests

Automated software testing is a mistake proofing (poka-yoke) solution for software development.

The way automated testing works is that software code is written that tests the software code of the application. This automated testing code test that business rules are correctly being followed by the code in the application.

So for example, a user should not be able to create a new account without entering password. Then you create code that does not allow an account to be created without a password. And you write a test that passes if this is true and fails if it is false.

The best implementation will then not allow deploying code to your production environment until the code has passed all the automated tests. So if a software developer changes the code, the automated tests are all run and if there is an error noted by the automated testing the code cannot be deployed to the production environment. So, in the example above, if somehow the changes made to the application code somehow now let an account be created without a password the test would fail, and the developer would know to fix the problem before putting the code into production.

Thus automated testing mistake proofs the process. Now the mistake proofing is only as good as the test that are added. Software development is complex and if the code has an error (based on the business rules) that is not tested then the code can be deployed to production and affect customers. But it is a huge help in preventing many errors from affecting customers.

It seems pretty obvious but until the widespread adoption of agile software development techniques and frameworks that make it easy to adopt automated testing (like Ruby on Rails) this sensible process improvement tool was used far less often than you would think.

Related: Combinatorial Testing for SoftwareMetrics and Software DevelopmentChecklists in Software DevelopmentGoogle testing blogHexawise software testing blog

More Reasons to Avoid Layoffs

Lay Off the Layoffs by Jeffrey Pfeffer

As its former head of human resources once told me: “If people are your most important assets, why would you get rid of them?”

In fact, there is a growing body of academic research suggesting that firms incur big costs when they cut workers. Some of these costs are obvious, such as the direct costs of severance and outplacement, and some are intuitive, such as the toll on morale and productivity as anxiety (“Will I be next?”) infects remaining workers.

research paints a fairly consistent picture: layoffs don’t work. And for good reason. In Responsible Restructuring, University of Colorado professor Wayne Cascio lists the direct and indirect costs of layoffs: severance pay; paying out accrued vacation and sick pay; outplacement costs; higher unemployment-insurance taxes; the cost of rehiring employees when business improves; low morale and risk-averse survivors; potential lawsuits, sabotage, or even workplace violence from aggrieved employees or former employees; loss of institutional memory and knowledge; diminished trust in management; and reduced productivity.

As bad as the effects of layoffs are on companies and the economy, perhaps the biggest damage is done to the people themselves. Here the consequences are, not surprisingly, devastating. Layoffs literally kill people. In the United States, when you lose your job, you lose your health insurance, unless you can afford to temporarily maintain it under the pricey COBRA provisions. Studies consistently show a connection between not having health insurance and individual mortality rates.

Related: Five Managerial Fallacies Concerning Layoffs – Honda has Never had Layoffs and has been Profitable Every YearThe Trouble with Performance Reviews by Jeffrey PfefferCutting Hours Instead of PeopleFiring Workers Isn’t Fixing Problems

Toyota Stops Lines – Lots of Lines

The practice of stopping (either the machine automatically detecting a problem and stopping or a person stopping) the line when a problem is detected is part of Jidoka. Jidoka is also highlighting and making problems visible. Jidoka and Just in Time are the two pillars of the Toyota Production System. Today Toyota practiced Jidoka on a large scale: Toyota Halts Sales of Eight Models After Recall

Toyota Motor, still struggling to resolve a problem with accelerator pedals, said Tuesday it would temporarily stop selling and building eight models in the American market, including the popular Camry and Corolla sedans

“This action is necessary until a remedy is finalized,” Robert S. Carter, a Toyota group vice president, said in a statement. “We’re making every effort to address this situation for our customers as quickly as possible.”

Toyota said it would immediately stop selling the Camry, Corolla and Avalon sedans, Matrix wagon, RAV4 crossover, Tundra pickup, and Highlander and Sequoia sport utility vehicles. It will also stop building those models the week of Feb. 1. All of the vehicles are assembled in the United States or Canada, at a total of five plants.

The models affected accounted for more than a million sales in 2009, 57 percent of Toyota’s American total for the year.

The most recent recalls follow what Toyota insisted was a companywide effort to improve quality that was started by Katsuaki Watanabe, who served as its president before he was replaced last year by Akio Toyoda, grandson of the company’s founder.

My guess is there are quite a few people in Toyota that are getting a frustrated that they continue to have problems that they have been unable to successfully address. This strikes is as the kind of action initiated near the top of the organization chart to remind the organization that problems must be addressed immediately. It is not ok to continue business as usually when problems have not been addressed in the Toyota Production System. Toyota is capable of failing to live up to the principles of lean manufacturing. But they also seem to understand this risk and continue to strive to improve. To succeed though they need to improve results – intentions alone are not enough.

Related: Cease Mass Inspection for QualityRecalls at Toyota and SonyReacting to Product ProblemsWorkplace Management by Taiichi Ohno

Lean Manufacturing Simulation (webcast)

This webcast, from the MIT Open Courseware initiative, shows a simulation (with legos). And in doing so explores the advantages of lean manufacturing methods.

Related: Red Bead Experiment Webcastone-piece flowApplied Quality Engineering EducationThe Lean MBA

Worse Hotel Service the More You Pay

The more you pay for your hotel room the more likely they will charge to provide decent WiFi in your room. Whether a company tries to rip you off with exorbitant prices, or lousy service, is just a function of their lack of respect for customers. Obviously it is cheap to provide decent WiFi (as staying at numerous cheap hotels shows – nearly all offer WiFi completely free).

Most expensive hotels show they do not respect their customers. Some actually do rise to the level of a typical budget, and cheaper, hotels and motels so it isn’t all expensive hotels that fail to meet this low standard. The management of those hotels come from the same school of management thought that produces our bankers.

Jeff Bezos captures one difference between poor managers (prevalent in many spreadsheet focused managers) and lean manufacturing managers with the quote: “There are two kinds of companies, those that work to try to charge more and those that work to charge less.”

Thoughts on: Hotel WiFi Should Be a Right, Not a Luxury

Related: Making Life Difficult for CustomersVerizon Provides Lousy Service = Dog Bites ManIs Poor Service the Industry Standard?

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