Blogger, Author, Customer Experience Fanatic, and Lean Practitioner Pete Abilla interviews leaders in Lean, Six Sigma, and Customer Experience.
Business operations must have a through and effective cleaning program that gets results on a daily basis.
Achieving and maintaining the highest possible cleanliness standards is really one of the easiest things a business can do on a daily basis. Implementing Lean practices and principles is really about a mindset and change management. Implementation Plan – Tasks, start dates, duration, responsibilities, and completion status.
To achieve the best results,  the affinitizing process is best performed by bringing all the team members or stakeholders involved into a room and allowing them to post sticky notes with single ideas on a board or flipchart. The goal of the Affinity Diagram group is to meld the perspectives, opinions, and insights of a group of people who are knowledgeable about the issues.
Highlighting the Struggle Finding the balance between the bold strokes of entrepreneurship and the structured constraints of strategy can create a whirlwind in a business. Find a balance between audacious entrepreneurship and the structure of Lean strategies can be a delicate balancing act, but one that must be mastered. The Impact on a Global Scale Green manufacturing and clean energy are getting attention on a global scale. Green manufacturing is a good idea in terms of the environment, and also for business on a global scale. There is a serious interest and commitment to green initiatives in the global manufacturing industry.
Creating an Environment of Success Lean leadership is a valuable but sometimes elusive quality in managers.
In a successful organization that inspires and grows leaders, lean leadership is practiced at all levels.
The Boeing plan is to use newer and more standardized manufacturing techniques for its new 777X jetliner, paving the way for more significant savings as it gradually feeds the changes back into existing assembly lines.
With standardization in the aerospace industry being limited, this is the perfect opportunity for Boeing to take advantage of lean production.
Like with any other tool in Lean Six Sigma, there are some steps you need to follow to get the most out of mistake proofing your projects. We sometimes depend on inspections conducted by workers to be fail safe for mistake proofing. The Strength of Tea in Sri Lanka The tea industry in Sri Lanka has been in place since 1867 and represents 2% of the GDP. Experts have studied the issue and have proposed the adoption of lean management on plantations across the tea industry. The same way you apply Lean to your physical production, there is a similar sale kaizen that will apply to your strategies.
A sales organization that operates with a focused Lean philosophy will benefit just as much as a manufacturing organization. Implementing the strategies will solely depend on where the comfort level is with each methodology and the desired outcomes. Whatever your choice is, combining the methodologies into a supportive and viable team can yield dynamic results. Conversations that occur around improvement of outcomes are always better than conversations centered around Lean principles.
The next logical step once outcomes are identified is to quantify those outcomes in terms that managers understand…money!
Once you have identified outcomes, quantified each outcome with potential cost savings, now it’s time to go to work. It costs between 100% and 300% of a new hires annual salary to replace them when they quit.
We hope that gave you a few things to reflect on while you take in the true impact on your organization of those numbers.
The Lead with Respect model is a radically different approach that engages staff and shows them the way forward!
Teamwork – Keep the focus on the overall success and quickly break down departmental silos.
Learn from Improvement Efforts – Instill and demonstrate the value of quality improvement efforts.
Practicing these Lead with Respect principles will create a more open and energetic work environment.
The mainstream approach to management is so deeply engrained that leaders tend to find it the most comfortable position to take. Even in your LEAN efficient organization, you may be burning profits that could be unimaginable to most.
This gives significant strength to the argument that a LEAN office is an important area of focus for those seeking higher profitability and customer satisfaction. Learn to trim the waist line of the administrative offices, with the same energy and focus as your manufacturing shop floor.
The term 5S is an abbreviated reference to five Japanese words that control workplace organization and housekeeping. Wednesday, April 13Richard Dean and Luke Markve will report on the Prairie Star District Annual Conference held April 8 to 10 in Des Moines, Iowa. If you have additional business to bring to the BUUF, please contact Richard Dean, President or Louise Markve, Secretary.
The BUUF highway litter cleanup is due again, especially since the snow came and stopped us from doing our fall cleanup. The Center for Disease Control (CDC) estimates there were 38 million food-related illnesses in the USA last year, resulting in 3,000 deaths. There are about 7 billion people in the world today; by the year 2050, there will be 9 billion people to feed. The Steering Committee has designated a special fund in memory of LaGretta Dean to be set aside for our building fund. On Dec 17, 2010, fruit vendor Mohammed Bouaziz, 26 years old, set himself on fire in Sidi Bouzid, Tunisia. It was a usual pattern in Tunisia: In arrogance the police stole his fruit and his scales, pushed him around, and humiliated him by slapping him in the face in front of friends and 50 witnesses.
The burning of a Koran in Florida set off rage in Afghanistan that is hard for us to understand.
Jeffrey Hatcher, playwright and member of UUCM in Wayzata, has written a play entitled a€?Three Viewings,a€? which will be presented at the Illusion Theater on Hennepin Ave. In the March 29 Star Tribune was an excellent article about the Dakota Unitarian Church in Burnsville, the only UU church in Dakota County.
Like most Unitarians, church members hold a variety of beliefs about what constitutes truth, God and religion.
We welcome everyone to our group, whatever your race, ethnic origin, religious perspective, sexual orientation, political philosophy, or economic condition.
The purpose of this Fellowship is to provide opportunities for persons to come together for the study and exploration of religions, philosophies, ethics and the inspirational and provide an atmosphere where one can develop and revise onea€™s own philosophy and beliefs. This Fellowship supports the statement of principles of the Unitarian Universalist Association and the principle of separation of church and state. Any person who has reached the age of majority (18) and is in sympathy with the Fellowshipa€™s purposes may become a member by signing the membership book and making a minimal contribution as established by the Steering Committee each year.
The regular meetings of the Fellowship shall be determined by the Fellowship itself or by any person or persons designated by it.
The Fellowship will work toward affiliation with the Prairie Star District and the Unitarian Universalist Association.
The Steering Committee shall consist of the officers and the chairs of the permanent committees, and it shall consist of not less than four (4) persons and not more than sixteen (16) persons. The officers will be chosen by ballot of the membership for the following positions: president, vice-president, secretary, and treasurer. The immediate past president shall also serve on this committee for a two-year period following his or her last term. The Steering Committee may call an Executive Session at its discretion; only members of the Steering Committee may attend these meetings.
The Steering Committee shall have general charge of the property of the Fellowship and the conduct of all its business affairs and the control of its administration, including the appointment of such committees as it may deem necessary. The nominating committee shall consist of three (3) members, at least two of whom are not members of the Steering Committee.
The fiscal year shall begin on January 1 of each year except for Fiscal Year 2011, which will begin on July 1, 2010 and end on December 31, 2011.
In the event of the dissolution of this Fellowship, all of its net assets shall be distributed to the Unitarian Universalist Association. Roberta€™s Rules of Order Revised shall govern the proceedings of all the meetings of the members and the Steering Committee. He interviews leaders in their respective fields and through these informal discussions we learn insights that you can apply immediately to your work today. Your facility gets dirty on a daily basis and your program must be effective to maintain standards.


In one internal support function, 75% of transactions took less than five minutes to process. With that said, 5S should be a problem prevention program and a way to identify and fix problems when they are still very small, thus preventing big problems.
Focus on the elements of 5S will start the process and it will be effectively expanding when coupled with the 5Y. When properly accomplished, it can provide insight and complete clarity to those both inside and outside the scope of the project.
The vision of an entrepreneur brings to mind a bold, unbridled risk-taker willing to bet everything for success, no matter what the odds. Without the restraint and focus of the engine design and aeronautical constraints of that design, the thrust produced would be a tempest unleashed and ultimately wasted. Even though new environmental regulations are cropping up around the globe, leading companies are very focused on taking the initiative. Yes, managers and leaders can completely miss having the necessary skills and still maintain their positions. Organizations that create true leaders understand that to survive and prosper we must improve, and to improve we must change. As competition heats up between two aerospace giants, Boeing and Airbus, Boeing is looking at every opportunity to produce their new 777X as the most cost effective and highest quality aircraft in production.
This approach will draw significantly on lean production lessons learned from outside the aerospace industry. While this does have some validity, humans are flawed and naturally prone to errors, even to the smallest degree. When you measure productivity in the industry, plantation workers are plucking an average of 18kgs a day.
These studies have clearly shown that a Lean approach to the industry will bring resolution to the endless labor disputes, reduce the lack of productivity, and boost quality across the board.
Even though the philosophy is geared to the manufacturing process, it has immense flexibility across all sectors and logically should fit with your sales operations.
Lean brings to the table efficiencies along with a deep understanding of customer needs and desires.
Lean tools include the 5S system of workplace organization, standard work, one-piece flow, quick change-over, pull systems and total productive maintenance.
Lean is a mindset and comes from the heart, based on desires to change to improve outcomes. Agree upon one outcome that can be addressed with Lean thinking and principles of the practice.
The concept is made up of these elements: Go and See, Challenge, Listen, Teach, Support, Teamwork and Learn. These operations are continually looking for ways to remain efficient, effective and profitable. If you understand that that well over 50% of operating expenses are in labor and that 60%-80% of the costs of completing an order are administrative, you might be getting the hint of where to start.
Efficiencies with the administrative team can create a profitability never before imagined in manufacturing.
Sperber began his presentation by asking us, a€?Who is responsible for food safety?a€? Is it the producer (food business), the farmer, or the consumer? Sperber also addressed the question, a€?Is capitalism ruining the environment?a€? In some ways, yes. No matter what industry you operate in, cleanliness is a crucial point of measure for customers and employees alike. Thats where Lean principles and the 5S’s need to been practiced across all aspects of your business, not just the manufacturing floor or in customer interactions and service delivery. Even though many organizations across the service industry are adopting Lean principles and practices, the concept just hasn’t been sold. Even though many organizations across the service industry are adopting Lean principles and practices, the concept just hasn’t been sold. The remaining 25 %, more complex transactions, account for 60% of the total time expended daily.
For some, a lack of understanding of what a 5S program should be relegates the process to a very effective housekeeping program for the organization with embracing the results of quality improvement.
When we observe something out of place with 5S, the process should be repeated until we find the root cause and take action.
When you see a loose part or fluid pool on the floor, don’t just pick it up or clean it up. The idea is to go for the gut feeling rather than rational pontification, and speed rather than deliberation is the order of the day. It serves as both a screen that innovation must pass and a yardstick for evaluating the success of that innovation.
With proper design, structure and focus, the thrust of the jet engine can be precisely controlled to achieve the maximum desired effect.
Some develop these skills through experience and education, but still miss that key element that makes them great.
When these leaders possess and practice the five characteristics listed above, change occurs at a much higher rate, with a significant increase in quality. It will also provide Boeing the opportunity to significantly impact other production lines. The business has been managed (ruled) under the age old feudal work structure that has been in place since the inception of the industry. Because of the financial distress to the plantations and the government, all parties seem to be open to implementation of a lean management system.
Individual effort is important to the equation, but individual effort must be focused on the common goal or outcome. Others may choose to use Six Sigma first as they wish to gain control of specific processes.
Six Sigma utilizes DMAIC along with other tools, such as Histograms, Pareto charts, the 5 Why’s, along with Fishbone diagrams to achieve specific results. Start the meeting by getting an understanding of exactly what outcomes in the organization they would like to see changed and improved.
Your manager may want to argue Lean principles, but they are woefully hesitant to argue against saving money, especially when those costs savings could significantly boost the bottom line. It has been trending for years, and organizations continue to hide from the real issues or paste over them by throwing around money and promotions to appease the staff. Understand that the true mission of a leader is to completely satisfy the customer, and to do that all your available resources must be onboard and working in complete harmony with each other.
The real question is: when was the last time you took a look at your administrative offices?
Well, behind those doors over there could be significant opportunity, which remains largely ignored.
Administrative activities take place behind the scenes, but impact your bottom line far more that you can imagine.
The course of history has been forged by these heroic men and women of the Armed Forces who honorably served and sacrificed for their nation. Within the 5S Principles (Sorting, Set-In-Order, Shining, Standardization, and Sustaining), cleaning is well represented. So many understand the value of Lean principles, but just cannot get their head wrapped around how it would apply to them in the services sector. These examples can be a huge drain on productivity and are typical for many service processes.
Making continuous improvement will then make a permanent change in the culture and produce the change you are seeking.
The elements of the 5S program (Sort, Set in order, Shine, Standardize, and Sustain) are often mistaken for effective housekeeping. With that in mind, you must use the 5Y (why, why, why, why, why) until you have determined the root source of the problem. Your 5S has led you to the problem, now expand the 5Y until you clearly can grasp why those situations exist and how they will reconcile. Created in the 1960s by Japanese anthropologist Jiro Kawakita, it can be used very effectively to organize the ideas extracted from a brainstorming exercise where people from diverse and unrelated departments come together to solve a complex problem. Robber barons and moguls built the industrial and financial strength of this country through bold and audacious entrepreneurship. Lean strategies allow and encourage frontline employees to be creative, while ensuring that they remain on the same page with the rest of the organization and pursue only worthwhile opportunities.
These same companies are finding that the Internet of Things (IoT) with connectivity, software improvements and innovative devices are becoming valuable tools in improving green manufacturing.
Then there are the few that leadership is a natural skill that is simply multiplied through education and experience. Change is in fact the cornerstone of the lean practitioner, and lean leadership is at the forefront of that energy. Automation will not accept a defect in the process, or create a defect in the process, or allow a defect to be passed to the next process. Turmoil has shaken the industry in the past few years with protracted labor disputes and significantly reduced productivity.


The problems of the industry clearly can be addressed and resolved through the use of lean management. Having a manager that is well-respected, energetic and eager to apply a lean approach to business is the perfect combination that will make employees less apprehensive and more interested. When you understand the customer, then you can efficiently tailor a process that exceeds expectations and creates a better environment for closing the sale. Without everyone working towards the same goal, with the same focus and energy, the desired results will always be elusive. These tools create a powerful, results driven focus in an organization and will inspire energized teamwork throughout. You have been spending weeks prior to this meeting rehearsing the concepts, practicing every conceivable objection and compiling reams of data. Use your Lean practice and thinking to get demonstrated results and quantify those results financially.
Unfortunately, the failure of those efforts are starting to hit home with organizations and leaders.
Finding that ideal sense of purpose is not impossible, but it all starts with you, the leader. Can you say, with confidence, that your administrative offices are run with the same efficiency as your manufacturing floor? The decision-making process usually comes from a dialogue about standardization, which builds understanding among employees of how they should do the work.
Their individual acts of selfless bravery should be a reminder to all of us that there is a cost to being a part of this great nation. Often enough, asking 5 times is not enough, and the more you ask why, the deeper you dive into a problem.
To ensure the best results, you must create an atmosphere of trust and safety, where opinions are free to flow without any constraints.
However, that type of unbridled action can just plain scare some entrepreneurs into a state of inaction.
Entrepreneurship at its most pure level brings vision, spirit and creative innovation to the business.
All of these efforts to improve clean energy and climate change have a direct impact on manufacturing. These new devices and their connectivity are proving to be efficient and effective in their quality improvement initiatives.
Adisho was previously with Toyota, where he oversaw manufacturing at their plant in Kentucky. This is a method at the disposal of Lean Six Sigma practitioners to reduce and eliminate errors in process and procedures. As with any other process, you must consider the cost of implementing poka-yoke mistake proofing methods.
These factors has shaken the financial stability of the government, and change has been called for. When the plantation managers have a clear understanding of the challenges truly faced by the workers, and the workers clearly understand the need of the plantation managers, life could be revived in the industry.
Customers will organically become more loyal, and you will also attract new business that was hidden before by a clumsy process. To put this into a modern perspective, during the past decades of all the volunteer military, less than 1% of eligible Americans have served their country. From gum on the sidewalks and entrances, to dust on framing, dirty floors and unkept or unsanitary restrooms, customers see all and judge you accordingly. Without those situations challenging them daily, they just don’t understand the connection. In the service industry, the customer is the product and their satisfaction is the focus of the process. Add to that unwavering support from the top and encouraging teamwork at all levels, and you will have found the right way to apply Lean practices to your service organization.
It is crucial to understand the intent of the 5S program and couple that with the 5Y to ensure that your results are quality focused.
Everyone in the organization must understand the purpose of 5S and why it must be embraced for what it is.
The same quality and thoughtful preparation that goes in will provide the absolute best results.
Whether it is a reduction in auto emission standards or clean energy efforts, manufacturing will be at the forefront of the initiatives. The connectivity created by the industrial Internet makes it easier to track resource consumption. However, we do know that if we create the proper environment, provide educational opportunities and expose people to the proper experiences, leaders naturally float to the top. In previous wage agreements, pluckers have been given wage increases, which improved their personal standard of living.
Sales is all about being in perfect harmony with customers, and a Lean sale philosophy can and will deliver! Lean is an important complement to Six Sigma and fits well within the Six Sigma DMAIC process.
However, your boss has clearly indicated that they are skeptical and tells you it’s going to be a hard sell to win the day. Cordileone×Customize & ShareYou can add your own message to the quote and share it with your friends! For manufacturing or other operations that have no physical customer presence, you are not off the hook. They take you from cleanliness to an in-depth exploration of understanding and quality improvement. There have been examples on manufacturing floors where their zeal to achieve the 5S’s has resulted in a state of hyper cleanliness.
Housekeeping and cleanliness are valuable, but don’t get carried away down the wrong path.
Unfortunately, some of these initiatives have fallen short or lack support on a global scale.
When companies are reducing waste and energy in their manufacturing processes, they gain a significant awareness of the importance of green manufacturing.
However, much to the dismay of management, pluckers continued to be frustrated in their work, and absenteeism and attendance continued to decline. Before you know it, successful outcomes will transform themselves into Lean successes without a heated debate of principles. It should bring pause and reflection to every American that so few are defending the nation and paying the ultimate sacrifice for freedom. Your employees are customers and they are critical of cleanliness in the businesses they frequent.
By practicing the proper 5S principles with cleanliness with the same attention and focus as the rest of your operation, you will be on track. But when there is too much strategy and structure applied in business, it can choke a business, restrict growth and dampen innovation. As an example, experts compare the current climate of 2015 China to the climate of 1974 Pittsburgh. These issues are just a glimpse at the problems that are strangling the livelihood of the industry.
The conversation is going to be easier than you think, when you keep things in the proper perspective. Those same employees bring that critical eye into your business and evaluate it with the same intensity. From the outermost perimeter of your property to the inner sanctums of the facility, the 5S principle must be exercised diligently with cleanliness. They understand the dynamics involved in leadership building and have become very adept at identifying potential very early on and nurturing that potential. If your manufacturing facility is dirty, you are sending a strong message to your employees that you don’t care about their comfort, health and welfare.
If your focus is one lean, those issues will get quickly resolved without a clear understanding on why they happened. These organizations create an environment of success for leaders, and the potential then rises.
Unfortunately, cleaning services are one of the first areas looked at when cost savings must be achieved in an organization.
Allow the participants to discuss the shape of the chart, any surprising patterns, and especially reasons for moving controversial notes. It’s a never ending downward spiral that can eventually become very costly when you try to recover.



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