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Mainly I tag posts I think I will want to find easily. But this might also provide an interesting collection to browse for visitors. Recommended Posts: Better and Different - Management Advice Failures - The Purpose of an Organization - Management is Prediction - Change is not Improvement - Illusions - Management Improvement - Bad Management Results in Layoffs - Experiment Quickly and Often
At the core of the company’s success is the Toyota Production System, which took shape in the years after the Second World War, when Japan was literally rebuilding itself, and capital and equipment were hard to come by. A Toyota engineer named Taiichi Ohno turned necessity into virtue, coming up with a system to get as much as possible out of every part, every machine, and every worker. The principles were simple, even obvious - do away with waste, have parts arrive precisely when workers need them, fix problems as soon as they arise. And they weren’t even entirely new - Ohno himself cited Henry Ford and American supermarkets as inspirations. But what Toyota has done, better than any other manufacturing company, is turn principle into practice. In some cases, it has done so with inventions, like the andon cord, which any worker can pull to stop the assembly line if he notices a problem, or kanban, a card system that allows workers to signal when new parts are needed.
Very true, except one thing. Toyota’s innovation is not limited to process and execution. Toyota’s long term vision results in very dramatic innovation (that granted is not getting the press today - check back in 20 years, I think you will be reading about it then). For some examples see: Toyota’s Partner Robot, Toyota as Homebuilder, Toyota Engineers a New Plant: the Living Kind and The Birth of Prius.
A company truly driven by a focus on continual improvement, respect for all employees and reasonable executive compensation might be a company serious about adopting Deming and Toyota management principles. It is hard for me to imagine such a situation that doesn’t truly seek, as the primary aim of the organization, to benefit many stakeholders (workers, owners, suppliers, customers…) not just executives (or just executives, board and owners…).
Related: Toyota Management Develops the New Camry - Better and Different - Deming and Toyota - Toyota Keeps Improving - More Positive Press for Toyota Management - Good Execution is Important
Well, this doesn’t sound very well thought out. Bonuses often distort behavior. Dr. Deming was not against such targets and bonuses because he thought they would not result in bugs being fixed: Dr. Deming on the problems with targets or goals. It is a question of how that will happen. The system being distorted is the most likely result of any such system.
Everyone worked even harder on the third day. On the fourth day, however, the well had started to dry up. The testers ran, re-ran, and re-ran again the test cases, but they could only find a handful of issues. The developers strained the issue-tracking system, constantly reloading the “unassigned bugs” page and rushing to self-assign anything that appeared.
And then something strange happened at lunch. Instead of going out to eat with his usual teammates, one of the developers went out with a tester. Soon after, another developer went out with another tester. Within a few minutes, almost all of the developers had paired up with testers.
As the developers returned from lunch, they immediately got to work. Instead of scavenging for newly found bugs, they worked on “code refactoring” and new functionality. And as soon as they deployed their changes, testers found bugs — minor, obscure bugs that a developer could easily overlook. And just as quickly as testers found bugs, the developers were able to fix them and re-deploy. By the end of the day, developers and testers had earned an average of $120.
Why is 37signals so arrogant? by Don Norman
I don’t agree. Not compromising leads to solutions that are unlikely to be all things to all people. But with an intelligent and knowledgeable leader will lead to excellent solutions for those that share desires. Now I don’t think this is the best strategy, especially for growth. But it can be an excellent strategy for startup, innovators and those seeking 1,000 fans.
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Here is updated data from the UN on manufacturing output by country. China continues to grow amazingly moving into second place for 2006. I plan to write more on this data in the Curious Cat Investing and Economics Blog. UN Data, in billions of current US dollars:
| Country | 1990 | 2000 | 2004 | 2005 | 2006 |
|---|---|---|---|---|---|
| USA | 1,040 | 1,543 | 1,545 | 1,629 | 1,725 |
| China | 143 | 484 | 788 | 939 | 1096 |
| Japan | 808 | 1,033 | 962 | 954 | 929 |
| Germany | 437 | 392 | 559 | 584 | 620 |
| Italy | 240 | 206 | 295 | 291 | 313 |
| United Kingdom | 207 | 230 | 283 | 283 | 308 |
| France | 223 | 190 | 256 | 253 | 275 |
| Brazil | 117 | 120 | 130 | 172 | 231 |
| Korea | 65 | 134 | 173 | 199 | 216 |
| Canada | 92 | 129 | 165 | 188 | 213 |
| Additional countries of interest - not the next largest | |||||
| Mexico | 50 | 107 | 111 | 122 | 136 |
| India | 50 | 67 | 100 | 118 | 130 |
| Indonesia | 29 | 46 | 72 | 79 | 103 |
| Turkey | 33 | 38 | 75 | 92 | 100 |
“The reasonable man adapts himself to the world; the unreasonable one persists in trying to adapt the world to himself. Therefore all progress depends on the unreasonable man.”
- George Bernard Shaw, Man and Superman
That quote sprang to mind when I read the great post - In praise of the lazy employee
My view of myself places me in both of these camps (lazy and unreasonable). But, honestly, I have become more reasonable over time and while it makes me less difficult to put up with I think I am less effective (my performance appraisals are more positive so maybe I am wrong or maybe my opinion of performance appraisals is right).
Marissa Mayer speech at Stanford on innovation at Google (23 minutes, 26 minutes question and answers). She leads the product management efforts on Google’s search products- web search, images, groups, news, Froogle, the Google Toolbar, Google Desktop, Google Labs, and more. She joined Google in 1999 as Google’s first female engineer. Excellent speech. Highly recommended. 9 ideas:
(inside these are Marissa’s comments) [inside these are my comments]
Often people have trouble understanding Dr. Deming’s disapproval of arbitrary numerical targets. What he was trying to prevent is what many see every day, such as managing to quarterly earnings targets. There are several problems with numerical goals but in here lets focus on one. The change from managing for what is best for the business to managing to hit a target. Google Profit Trails Analyst Estimates; Shares Slide:
Great statement. And if more people could manage that way, one of the problems with numerical goals would be eliminated. But with so many organizations tying huge bonuses to meeting arbitrary numerical targets you will have a great deal of difficulty getting managers to hire 3 extra people this quarter, who will help the business, but will ruin their chance at a bonus. Or even if they just take a hit on their performance appraisal compared to the other managers that meet the headcount target - even if it meant turning away talent the organization could have benefited from greatly - and then the manager that missed their target loses out in the next promotion opportunity.
I am happy to own a tiny portion of Google and glad they are making decisions like this. Now just because I think there is a good case to be made for exceeding the targets that doesn’t mean that hiring more people is necessarily good. It is perfectly possible Google is hiring too many people and making a bad prediction about how these people will benefit Google in the long run. I am just saying I strongly support not tying yourself to short term numerical targets, if you predict a better decision requires taking actions that will cause the target to be missed.
Google increased profit by 28%, from the second quarter last year, to $925 million (and down from $1.0 billion in the first quarter of 2007). Lest you think personnel can’t really cost Google that much can it, just the stock based compensation in the second quarter reduced earning by $242 million in the quarter (an “expense” that wasn’t reported just a few years ago). Google had 13,786 full-time employees as of June 30, 2007 (up 1,548 in the quarter) - so that is over $17,500 per full time employee. If anyone at Google wants to talk I am open to considering an employment offer.
Every so often an article appears discussing the need to change focus from process improvement to innovation (and recently they are followed with quite a bit of blog talk). I disagree on several grounds. First you have needed to focus on both all the time. Second, it is not an either or choice. Third, the process of innovation should be improved.
I do not believe process improvement is bad for innovation. Bad process changes can be bad for innovation. But if we are looking at a research and development organization where the output is new products then process improvement would be focused on improving the processes to make that happen. The type of process improvement would be different than those made to manufacturing a product better.
Some six sigma efforts are little more than cost cutting efforts. And those efforts might claim a “process improvement” that is really just cutting costs in R&D. But we should not confuse bad management with the good practice of process improvement. Yes, cutting costs for the sake of cutting costs often leads to problems. Waste should be eliminated (which can reduces cost). Focus on eliminating waste. Eliminating waste in innovation activities is no worse than eliminating it anywhere. It might be more difficult to determine what is waste (that is where management skill and knowledge come into play) but the idea that process improvement (including eliminating waste is bad for innovation is something that should be rejected). And process improvement in innovation should not be limited to eliminating waste.
A good example of process improvement in innovation activities: Fast Cycle Change in Knowledge-Based Organizations (pdf format) by Ian Hau and Ford Calhoun, published by the Center for Quality and Productivity Improvement, University of Wisconsin - Madison.
Related: Better and Different - New Rules for Management? No! - Quality and Innovation - “New” Management Needs - Management Advice Failures
In response to Is Laying People off Really Anti-Lean?:
If you come into this situation and realize that you can implement some basic lean and six sigma principles and only need half the workforce to meet customer demand what do you do?
Layoffs are a failure of management. If the company has not been executing a long term strategy to respect people and manage the system to continually improve, manage for the long term, working with suppliers… it might be they have created an impossibly failed organization that cannot succeed in its current form. And so yes it might be possible that layoffs are required.
It is very easy to jump to layoffs as the “answer” though. While it is possible to construct a situation in which they make sense that such a hypothetical situation it rarely is the case that an organization is committed to lean and then makes layoffs. Instead they just think the same old way and mention the word lean since they see others doing it and layoff sounds like it is lean to someone that doesn’t know the first thing about lean thinking.
I would not see, “a focus on improving operating income above all else” as a lean way of thinking. Improving that is one focus among many that are needed to achieve long term success.
Does that mean a organization doing a great job of managing in a truly lean way may not find itself in a position where layoffs are necessary? No. Failing to predict and execute may have consequences and those may include layoffs. In your example things are confused a bit by separating the responsibility of getting into the mess from what to do next. Definitely, riding out a few poor quarters would be preferable. I have absolutely no question about that.
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Right on. In meetings writing down decisions (what is the issue, who is going to do what…) is very helpful. It is very easy for people to think people agree to some somewhat clear statements made in the meeting. Only later it becomes obvious several people have different understandings (sometimes this is even really basically know in the meeting but it is easier to let things slide instead of confronting the disagreement - but this is not helpful, it just means the issue is not properly address, it might make the meeting easier but that should not be the goal). Writing it down greatly reduces the chance of miscommunication.
Russell Ackoff also has some great stuff on the importance of documenting decisions - both to serve as guide posts to future action and to serve as documentation that can be examined over time to find historic weaknesses and strengths with decision making in the organization. The Team Handbook is a very good book for improving team meetings and team performance.
Ackoff on decision making (pdf):
• The justification for the decision including its expected effects and the time by which they are expected…
• The assumptions on which the expectations are based…
• The information, knowledge, and understanding that went into the decision.
• Who made the decision, how it was made, and when…
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If the output for working for the year is a square. And the job is to produce dark squares who do you pay more A or B? Of course it is a trick question, the squares are the same color. But it doesn’t look that way at first does it? Optical illusions provide evidence that you cannot always trust what seems obvious.
Dr. Deming’s red bead experiment provides some additional insight into the idea that our management systems often use “evidence” to support our believes when in fact the “evidence” does not mean what we think it does. Dr. Deming included the theory of knowledge (how do we know what we know) as one of the four areas of his management system. It is the areas of his work that is least appreciated and understood by managers today. Optical illusions provide a simple reminder of how easily we can think we know things that are not so.
Just as Toyota is always dissatisfied and looking for how to improve, it is important to question what you believe. Even when it is as obvious as the A square being darker than the B square. Understanding the ease with which we can reach false conclusions can be a powerful aid in improving management decision making.
Related: The Illusion of Understanding - Change is not Improvement - Performance Appraisal Problems - Dr. Deming on Performance Appraisal: “The fact is that the system that people work in and the interaction with people may account for 90 or 95 percent of performance” (from the introduction to the Team Handbook) - It is a mistake to think improving the figures is the goal
Optical illusion by Edward H. Adelson
3M in building spree to end capacity constraints
In the past, a 3M culture that viewed new investment with circumspection and an over-reliance on the Six Sigma management technique made it shy of building some needed capacity, Buckley said. “We got ourselves into a position in which we thought Six Sigma would come to our rescue. We all known that in reality it’s something that runs out of steam,” he said.
Well if you “know” that you are not properly executing a six sigma management system. Previous posts on this topic: Management Advice Failures - Change is not Improvement - Leaving Quality Behind? - Going lean Brings Long-term Payoffs. Often six sigma programs amount to cost cutting programs (which can easily run out of steam),; but that is so far from effective six sigma management that it isn’t really fair to equate a programing calling itself “six sigma” with the actual practice of six sigma management.
Still the CEO still seems to believe in lean six sigma:
Dave Gleditsch, Chief Technology Officer, Pelion Systems, makes many excellent points in: Transforming Your Business To Lean: Lessons Learned:
So ofter measures become the focus and the reason for improvement is obscured. Improvement should eliminate waste and improve value to the customer. Measures should help determine the success along that path but improving the numbers is not the aim, the numbers are merely proxies for that aim.
Successful management improvement is not about mindlessly applying quality/lean tools. The tools and concepts are very helpful but then people must make judgements about what is needed, what to emphasis, where to focus, how to proceed given the current organization…
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The newest data from the UN confirms most of the recent trends in manufacturing output - most notably that China continues to grow dramatically. The data also shows a stagnation in USA manufacturing output over the last several years, though the USA remains by far the largest manufacturer. The most significant news from this latest data, I believe, is that that manufacturing output growth in the USA has been slower than global manufacturing output growth from 2002-2005. This was not the case prior to 2002. I will be writing more on this data in the Curious Cat Investing and Economics Blog. UN Data, in billions of current US dollars:
| Country | 1990 | 1995 | 2000 | 2001 | 2002 | 2003 | 2004 | 2005 |
|---|---|---|---|---|---|---|---|---|
| USA | 1,040 | 1,289 | 1,543 | 1,460 | 1,471 | 1,488 | 1,545 | 1,493 |
| Japan | 809 | 1,217 | 1,033 | 857 | 807 | 886 | 962 | 964 |
| China | 143 | 299 | 484 | 527 | 573 | 664 | 788 | 895 |
| Germany | 437 | 517 | 392 | 389 | 407 | 490 | 566 | 594 |
| United Kingdom | 207 | 221 | 230 | 218 | 222 | 239 | 283 | no data |
| Italy | 240 | 226 | 206 | 205 | 218 | 259 | 295 | 291 |
| France | 200 | 233 | 190 | 185 | 192 | 228 | 256 | 253 |
| Korea | 200 | 233 | 190 | 185 | 192 | 228 | 256 | 253 |
| Canada | 92 | 100 | 129 | 119 | 120 | 149 | 170 | 196 |
| Brazil | 117 | 149 | 120 | 102 | 95 | 109 | 130 | 171 |
| Spain | 108 | 107 | 98 | 100 | 108 | 134 | 153 | 160 |
| Mexico | 50 | 55 | 107 | 110 | 111 | 104 | 111 | 122 |
| Russia | 201 | 104 | 73 | 77 | 54 | 64 | 92 | 117 |
| India | 50 | 60 | 67 | 68 | 72 | 84 | 100 | 116 |
Russ Ackoff once again does a great job of providing insight into management. I highly recommend A Little Book of f-Laws where Ackoff, with Herbert Addison and Sally Bibb, present 13 common sins of management, such as:
See: Deming’s thoughts on unknown and unknowable figures. A book with over 80 management flaws (er I mean f-Laws) will be published in January - you can even submit your own.
Related: Ackoff articles and books - blog posts on Ackoff’s ideas - Management Advice Failures
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What’s Driving Toyota? by Mel Duvall is an interesting, long article discussing Toyota overall and focusing on Toyota’s Information Technology systems.
“What strikes me about Toyota is, if you were to ask them if they have a technology strategy, they would probably say no, we have a business strategy,” says Philip Evans, a senior vice president at the Boston Consulting Group who has studied Toyota. “They have a very clear understanding of the role technology plays in supporting the business.”
This is such a simple point but so hard for many to truly adopt. IT is a support function. IT is a means to an end.
Great way to deploy software: nice use of PDSA methodology.
Related posts: Toyota IT for Kaizen - Planet Kaizen - Toyota Robots - management blog posts on information technology
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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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In our post on Manufacturing and the Economy we examined global manufacturing value added economic data. The World Bank has provided updated data, for 2002, which we provide below. In, Global Manufacturing Data by Country, we explored data from the United Nations through 2004 (on a related, but different, measure of manufacturing).
| Country | 1990 | 2001 | 2002 | 1990-2002% increase* |
|---|---|---|---|---|
| United States | 1,040,600 | 1,422,999 | 1,463,300 | 41 |
| Japan | 810,231 | 865,809 | 811,829 | 0 |
| China | 116,572 | 407,513 | No Data | 250 |
| Germany | 456,405 | 385,923 | 410,644 | -10 |
| United Kingdom | 206,718 | 220,429 | No Data | 7 |
| France | 228,270 | 217,534 | 192,279 | -16 |
| Italy | 247,914 | 203,248 | 216,177 | -13 |
| Korea | 64,604 | 117,575 | 129,449 | 100 |
| Mexico | 49,992 | 110,381 | 110,667 | 121 |
| India | 48,807 | 67,143 | 72,681 | 49 |
| World | 4,412,837 | 5,404,373 | 5,446,980 | 23 |
* 1990-2001 increase if no 2002 data available.
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This poster may do a better job, than my posts, of showing why posters and slogan are not an effective management strategy. Text from the poster: “If a pretty poster and a cute saying are all it takes to motivate you, you probably have a very easy job. The kind robots will be doing soon.”
Despair (link to the motivation poster shown here), offers many such de-motivational posters and note cards - well done satire, in my opinion, but they might be too much for some.
Along the lines of our post, Stop Demotivating Employees, the founder of Despair wrote a book entitled: The Art of Demotivation.
Another poster example: Ambition - The journey of a thousand miles sometimes ends very, very badly.
One of Deming’s 14 obligations of management was to eliminate slogans.
Also see:
Related: Why Extrinsic Motivation Fails - Dangers of Extrinsic Motivation - Alfie Kohn has some great books and articles on the problems with extrinsic motivation
I think the The Quality Movement Vs. The Innovation Movement by Bruce Nussbaum makes a mistake in calling the innovation movement separate from the quality movement.
Lets quote Deming on innovation from New Economics, page 10:
What is required? Innovation.
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