Curious Cat Management Improvement Blog: Deming, lean thinking, innovation, customer focus, continual improvement, six sigma.
Quotable Posts I want to Track

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

May 7, 2008

Toyota Execution Not Close to Being Copied

The Open Secret of Success

Toyota’s innovations, by contrast, have [focused] on process rather than on product, on the factory floor rather than on the showroom. That has made those innovations hard to see. But it hasn’t made them any less powerful.

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

April 18, 2008

The Defect Black Market

The Defect Black Market

It all started a week before, when the CTO of Damon’s midsize warehousing and transportation company in Northern California announced an innovative program to motivate employees and boost the quality of their logistics software. For every bug found by a tester and fixed by a programmer, both would get $10.

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 a bit harder the next day. Testers made sure to check and double-check every test case they ran, while developers worked through lunch to fix their assigned bugs. And it paid off. On that second day each had earned an average bonus of $50.

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.

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March 10, 2008

Pleasing Customers

Why is 37signals so arrogant? by Don Norman

The Brash Boys at 37signals Will Tell You: Keep it Simple, Stupid. Brash is an understatement. I was quoted in the article because of my article arguing that simplicity is highly overrated: the tasks that we do require tools that match the requirements, and these add complexity.

Yes, they are arrogant — and proud of it: “Arrogant is usually something you hurl at somebody as an insult,” Hansson said. “But when I actually looked it up — having an aggravated sense of one’s own importance or abilities’ — I thought, sure.” Park concludes his article by saying “Call it arrogance or idealism, but they would rather fail than adapt. ‘I’m not designing software for other people, ‘Hansson says. ‘I’m designing it for me.’ ” “I’m not designing … for other people.” I think that simple phrase speaks volumes. Thank goodness most companies recognize that this attitude is deadly.

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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January 15, 2008

Top 10 Manufacturing Countries 2006

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

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November 5, 2007

The Lazy Unreasonable Man

“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

They want to know why it takes five signatures to get something approved when one should do. They want to know why the forecasting effort should take two weeks each month when a bit of rethinking could cut 50% out of the work and possibly get better answers. They want to know why they’re tied up in bureaucracy when simplifying work would leave them more time to attend to customers’ needs and to come up with creative new ways to make progress for the company. They’re lazy enough not to take “We’ve always done things that way” for an answer; they want to figure out how to do more with less. They want to make more contribution than the 80-hour-a-week employee supposedly does and to do it with far less stress and strain.

As one demonstrably highly effective manager I knew has said (my paraphrase), “The effective people are those who put in a solid six hours a day working on the right things and then spend another couple of hours listening to people and to ideas; they typically are much more effective than those who work late into the evening.”

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).

August 9, 2007

Great Marissa Mayer Webcast on Google Innovation

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]

  1. Ideas come from anywhere (engineers, customers, managers, executives, external companies - that Google acquires)
  2. Share everything you can (very open culture)
  3. You’re Brilliant. We’re Hiring [Google Hiring]
  4. A license to pursue dreams (Google 20% time)
  5. Innovation not instant perfection (iteration - experiment quickly and often)
  6. Data is apolitical [Data Based Decision Making - this is true but as an operating principle requires people that really understand data. See: Data can't lie.
  7. Creativity loves Constraints [process improvement and innovation]
  8. Users not money [the opposite of what business school's teach business case]
  9. Don’t kill projects morph them

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July 19, 2007

Google Exceeded Planned Spending on Personnel

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:

The company hired more people than expected last quarter, Chief Executive Officer Eric Schmidt said on a conference call. Google added 1,548 jobs, mostly in sales, marketing and engineering, bringing its total to 13,786. “We overspent against our own plan on headcount,” he said. “We decided it was not a mistake. The kind of people we brought in were so good that we’re glad we did this.”

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.

July 4, 2007

Process Improvement and Innovation

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

June 3, 2007

Bad Management Results in Layoffs

In response to Is Laying People off Really Anti-Lean?:

Let’s say you, a Lean enthusiast, are named CEO of a mid sized manufacturing company. Let’s also assume your market has turned down and the constraint is clearly the market. Let’s also assume you need to improve operating income above all else. The final assumption is the company you inherited is not even good at mass production. They just stink at everything.

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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March 1, 2007

Write it Down

Why Write it down?

The longer I pursue Lean, the more I am amazed with its fundamentals. I may write more about this in the near future. Like the emphasis to write things down.

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):

Preparing a record of every decision of any significance, ones that involve doing something or (of particular importance) ones that involve not doing something. This record should include the following information:

• 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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February 12, 2007

Illusions - Optical and Other

Checkerbox Graphic 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

February 8, 2007

3M CEO on Six Sigma

3M in building spree to end capacity constraints

3M should complete the first of an 18-factory build-out in the third quarter, said its chief executive late Tuesday, as it makes up for years of underinvestment on the factory floor - even in its well-known household products. “Our major challenge will be getting all these plants launched,” said 3M CEO George Buckley at a Lehman Brothers conference. Buckley, who joined the St. Paul, Minn. company just over a year ago, has embarked on a global physical expansion program… Buckley said he realized the company was facing manufacturing constraints in several of its product lines.

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:

“We will continue to drive our growth agenda, which will be funded via aggressive productivity improvement efforts, such as global strategic sourcing and lean six sigma.”

(more…)

January 31, 2007

Transforming With Lean

Dave Gleditsch, Chief Technology Officer, Pelion Systems, makes many excellent points in: Transforming Your Business To Lean: Lessons Learned:

First and foremost, we should always keep the customer at the forefront of the planning and implementation process. A key to success is in being able to find the customer in every single metric you choose to measure your Lean transformation progress by.

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.

In truth, there are a variety of best practices and methods that will drive significant Lean improvements. American Standard had a significant variety of products and manufacturing processes

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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January 28, 2007

Top 10 Manufacturing Countries

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

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November 11, 2006

Ackoff’s F-laws: Common Sins of Management

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:

Managers who don’t know how to measure what they want settle for wanting what they can measure

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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September 5, 2006

Toyota IT Overview

What’s Driving Toyota? by Mel Duvall is an interesting, long article discussing Toyota overall and focusing on Toyota’s Information Technology systems.

Technology does not drive business processes at Toyota. The Toyota Production System does. However, technology plays a critical role by supporting, enabling and bringing to life on a mass scale the processes derived by adhering to TPS.

“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.

As with almost all of its technology implementations, Toyota started small, carefully rolling out the portal to its Lexus dealers as a test. While it worked out the bugs, it continually expanded the offering, eventually making it available to all 1,200 of its U.S. Lexus and Toyota dealers.

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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August 31, 2006

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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August 16, 2006

Manufacturing Value Added Economic Data

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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August 13, 2006

Eliminate Slogans

De-motivation Poster

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

July 4, 2006

Quality and Innovation

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.

Wow. It makes sense. The father of quality, of course, was Dr. W. Edwards Demming, and he preached for a very long time before he was really heard. In fact, as I recall, Japanese companies first accepted Demmings teachings long before U.S. and European corporations.

Lets quote Deming on innovation from New Economics, page 10:

No defects, no jobs. Absence of defects does not necessarily build business… Something more is required.

What is required? Innovation.
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