Not Lean Retailing

Renovating Home Depot [the broken link was removed], Business Week

It is always dangerous to make too much of a magazine article, but Home Depot seems to be moving away from lean thinking in the following examples, to me anyway. The Home Depot founders:

allowed store managers immense autonomy. “Whether it was an aisle, department, or store, you were truly in charge of it,” says former store operations manager…

These days every major decision and goal at Home Depot flows down from Nardelli’s office. “There’s no question; Bob’s the general,” says Joe DeAngelo, 44, executive vice-president of Home Depot Supply and a GE veteran.

Nothing is wrong with major decisions being made by the leaders but the article leaves the impression many non-major decisions are centralized too. That is a problem for those who believe in management improvement ideas including lean thinking.

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Executives Participating in Kaizen Events

The Masco Mapmakers [the broken link was removed] by Bill Waddell

Guys from Brasscraft or Morgantown Plastics might go to a Delta faucet plant for the event – and note that these are executives, not factory level folks – that spend the week working on the kaizens. Of course, the Grand Kaizens are not the only ones. Individual plants hold their own kaizens by the hundreds. The primary purpose of the Grand Kaizen is to spread the lean message throughout the company. They learned that having the top people work hands-on in a kaizen was a lot more effective than sitting them down in a big room and subjecting them to a Power Point description of lean.

Getting executives to participate is a great way to have them learn a new way of thinking.

Masco Companies Learn Lean Manufacturing and Improvement Methods [the broken link was removed].

Lean thinking articles

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Made in the USA

Is ‘Made in U.S.A.’ back in vogue? [the broken link was removed]

As the need for speed in fashion retailing becomes ever more crucial to merchants, industry observers say “Made in U.S.A” is once again looking more attractive to some U.S. retailers versus importing from China.

The company used to import 70 percent of its merchandise from China and elsewhere and manufactured a smaller 30 percent of it in the U.S. Today it manufactures 60 percent locally and imports 40 percent, according to CEO Moshe Tsabag.

By shifting manufacturing back home, Tsabag said he’s able to deliver his order to retailers in about 45 days versus the 120 to 150 days it would take to source the same items from China.

More evidence of the benefits of “lean manufacturing,” though it seems they are getting only a few benefits (reduction of waste, faster resupply of “hot items”) and they may well not know about lean thinking. By studying and applying lean ideas they should be able to reduce the 45 day turn-around time. Perhaps they should read the Fashion Incubator blog [the broken link was removed].

One more interesting bit of fashion news: Amazon.com bought [the broken link was removed] an internet clothing retailer based in Madison, Wisconsin: shopbop.com. I don’t get it. We will have to see if time shows what Bezos sees that I don’t.

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Theory in Practice

Theory Meets Reality In The Heartland [the broken link was removed] by Bill Waddell:

An old boss of mine was fond of saying, “There are few things in life more tragic than to see your beautiful theories murdered by a gang of brutal facts,” usually when I approached him with a hare brained idea about turning one of our manufacturing systems inside out.

Those who only think about theories don’t accomplish much. And those that don’t have theories don’t either. To achieve success, theories need to be put to the test and modified as evidence shows flaws in the theory.

Knowledge is built upon theory… Rational prediction requires theory and builds knowledge through systematic revision and extention of theory based on comparison of prediction with observation.” (Page 102, The New Economics by W. Edwards Deming).

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Lean Manufacturing Success

K&S makes first shipment to China [the broken link was removed] by Buzz Ball

The award was given for K&S Wire’s continuous improvement in manufacturing excellence and its implementation of “lean” enterprise principles into its everyday operations.

It is because of these principles that Schwartz was able to make the announcement about the shipment to China.

“We took the order to construct 111,000 wire frames that will hold flip-flops,” said Schwartz. “Because of our ‘lean’ principles, our price was better than could be found in China. This is a first for us and I hope we will have many more in the future.”

K&S Wire manufactures a variety of steel CNC wire forms, grills, grates, guards, display units and custom products for various other manufacturers and for consumer use.

Executive Vice President Dave Padgett said the employees manufactures 20 to 25 different items every day.

The company recently completed a 30,000 square foot addition, which is the sixth expansion in the company’s history. The work force has grown from three in 1995 to between 90-110 this past year.

It is great to see such success stories in the press.

More lean thinking articles

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Lean Retailing

Teaching the Big Box New Tricks [the broken link was removed, *sigh* yet another website fails basic long term thinking related to usability, while saying they are aiming to help others adopt better management practices.]

Tesco in Britain has been a pioneer in lean provision for more than a decade. In the mid-1990s, as he looked at the opportunities for retailers provided by the emergence of lean logistics, Graham Booth, Tesco’s supply-chain director (now retired) had a very simple insight: A rapid replenishment system triggered by the customer would work in any retail format.

Book excerpt from Lean Solutions.

The consequence, in terms of performance, is remarkable. Total “touches” on the product (each of which involves costly human effort) have been reduced from 150 to 50. The total throughput time, from the filling line at the supplier to the customer leaving the store with the cola, has declined
from 20 days to five days.

And Tesco is moving into the United States retail market in the West Coast in 2007: Wal-Mart, Kroger, Safeway better watch out. The British are coming! by Parija Bhatnagar, CNNMoney.com “Tesco indicated that it will spend more than $400 million a year to build its U.S. stores. Langdoc estimates that the initial investment could pay for 100 to 150 stores.”

Previous Lean Retailing post.

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Manufacturing’s Influential Thinkers

Manufacturing’s Influential Thinkers and Doers [the broken link was removed] by John S. McClenahen

This article includes many of those I feel have contributed to the improvement of management over the last 35 years including: W. Edwards Deming, Taiichi Ohno, Shigeo Shingo, Gary Hamel and Eliyahu M. Goldratt.

However, “the best manufacturing thinkers of the last several decades” are Taiichi Ohno and Shigeo Shingo, contends Mercer’s Slywotzky. Ohno was a Toyota Motor Co. vice president and Shingo a consultant. In laying out the principles now often collected under the label “lean,” they challenged the prevailing notion that manufacturing had to be done on a large scale with long runs and large inventories. They challenged the notion that quality control was something done at the end of the production line. And they challenged the notion that a production line keeps running no matter what. “What they introduced went 100% against the grain and the mindset of great manufacturers of that time, both inside Japan and outside Japan,” Slywotzky stresses. The famed Toyota Production System, which emphasizes reducing waste and eliminating defects, is a product of their work. Its impact can be seen at Toyota, the “hundreds of Toyota suppliers” and “the hundreds of companies in the West that, with a 10- or 15-year lag, sometimes a 20-year lag, began to rethink and change their manufacturing,” Slywotzky says.

Related Posts:

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Deming’s 14 Obligations of Management

Deming and his 14 Points [the broken link was removed] with comments from the Random Thoughts from a CTO blog.

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La-Z-Boy Lean

La-Z-Boy changing production lines to compete with China [the broken link was removed]:

But in an attempt to better compete with the overseas market, the Neosho plant, along with six others in its division, is transitioning to the Lean Cellular Manufacturing method. In the new concept, the chair or sofa is manufactured by a team within a cell, thus eliminating separate departments. No jobs will be lost in the transition from batch-and-queue to lean cellular.

“Basically, we will have teams building the chairs from start to finish,” said La-Z-Boy Midwest Human Relations Manager Billy Meyer. “Right now, we have three cells up and running, but by the end of the transition, we will have 37 cells.”

Great news. It is good when companies take the improvement strategy to cope with changes in the marketplace.

The primary purpose of the new concept is to increase product numbers. The cells have become so efficient that it has cut the manufacturing time of a chair down from two and one-half days to just three hours.

“This is now a three-hour process from start to finish in the cell, “said La-Z-Boy Midwest production manager Bill Snow. “The process ends with a 12-point inspection. The cell members will not get paid for the piece until it is taken to where it will boxed. But eventually, boxing will take place in the cell as well.”

I agree with Mark Graban that a piece rate pay system is a bad idea.

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Innovation at Toyota

The Birth of the Prius by Alex Taylor III:

By the end of 1993 the development team had determined that higher oil prices and a growing middle class around the world would require the new car to be both roomy and fuel-efficient. Other than that, they were given no guidance. “I was trying to come up with the future direction of the company,” says Watanabe, who headed corporate planning at the time. “I didn’t have a very specific idea about the vehicle.”

Seems like a good job of providing a vision of what was needed without overly restrictive targets and goals (See: Targets Distorting the System).

In a plan he submitted to Wada in 1994, he wrote that the introduction of an improved engine and transmission system could boost fuel efficiency by 50%. But that wasn’t audacious enough for Wada, who didn’t want to be remembered for producing yet another Japanese econobox. “It was not enough to be a simple extension of existing technology,” Wada says. One possible solution intrigued him: a hybrid power system.

While targets and goals can distract from improvement some guidance is useful. If the desire to is have incremental improvement one strategy may be reasonable but if the desire is to aim for huge improvement another strategy is likely required. In general target are far too specific and overused so as a general rule I am inclined to be biased against targets. However the proper use of “soft” targets (doubling or in the range of 10% for example) to define the scope of an effort make sense.

If Toyota can continue to reduce costs, and it most probably will, the potential for hybrids may be nearly unlimited. With its huge headstart, better technology, enormous scale, and powerful will to make hybrids an everyday alternative to the internal combustion engine–a combination no other auto maker can match–it’s hard to see Toyota not dominating the industry for years to come.

Investing in innovation is risky. If successful, the benefits can build a competitive advantage that is difficult for others to eliminate. However, others will try and if you fail to execute as well in the future those benefits can disappear quickly. Toyota shows few signs of letting others catch up though.

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