Lean and safety go together like peanut butter and jelly. Safety should always come first. Whether the company is trying to implement lean or not. Safety is #1.
The automotive facility I was working at was one of the many places that claimed safety first in everything they did. It wasn’t until the management saw it ranked nearly last among facilities owned by the corporation. This is when the transformation took place.
Safety became a daily discussion in every area. A safety committee formed by employees. Safety bingo with a cash payout began. But the biggest change was came within the management team and how they handled safety concerns and issues. When an accident did occur all management was required to participate in understanding why it happened. Also, anytime there was a requisition making the facility a safer place it was signed…no questions asked. No ROI.
Within two years, the facility was in the Top 5 worldwide for the corporation for safety. The facility surpassed 2.5 million man hours worked without an accident. Employees were correcting other employees when it came to safety concerns.
Actions around safety were clear and concise. There was no room for misinterpretation. A 40 year veteran and amazing tooling engineer got sent home for one week with no pay because he did not lock out / tag out the machine before he went into it. It was shocking but sent a statement.
Contrast that to another facility I was in a few years later where the hearing protection rules were vague and unclear. When approached about this the management team was defensive and was more concerned about the inconvenience of dealing with hearing protection. Two years later the facility had four cases of hearing loss.
Lean or not the automotive facility was truly dedicated to safety.
- Safety first is a mindset. It isn’t just something you do. It is something you believe.
- Being safe and believing in safety are different things.
- The actions of a leadership team give true insight into their belief around safety.
Everyone is familiar with visual management. A concept lean utilizes to quickly show if the condition is normal or abnormal. Recently, I had a situation where visual management wouldn’t work and I had to use tactile management. I used the feel of something to no if that was the correct object or not.
I go through spells where I get horrible headaches in the middle of the night. When I get them, it happens for several nights in a condensed time and then won’t happen for months. I have to sit up and close my eyes without my head leaning against anything because it would cause it to hurt so badly.
I hate turning on the lights in the middle of the night. I don’t want to wake others. Plus, it makes my headache worse when I flip on the lights and my eyes have to adjust rapidly to the flood of light.
I would search the medicine drawer in the dark looking for the right headache medicine. It would take forever and most of the time I would end up turning on the lights.
Finally, a solution for searching for the medicine came to me. I taped a cotton paid to the outside of the bottle so I can quickly find the medicine without turning on the lights. Sometimes the simplest things can have the biggest impact.
Visual management wouldn’t work in the dark, but tactile management would. It is something the blind deal with everyday. They use feel to read braille.
Are there ways you could use tactile management?
One of the most valuable lessons I have learned is the importance of employee involvement in creating improvement within an organization. Working for the automotive supplier to create standard work instructions was time in my learning.
I have an industrial engineering degree. I had been certified in Ready-Work Factor and MTM motion-time analysis tools. I was taught how to analyze every slight movement a person makes and how to determine the amount of time it should take. I was the snot-nosed, arrogant, young engineer telling employees how to do their work quicker. I can count on one hand how many of the work instructions I wrote were actually followed for more than one day.
At the automotive supplier, my manager and I took a different approach. When going to an area to document the work standards, we pulled several people off the floor across all shifts to help. The teamwork between everyone was fantastic and my eyes were opened in three ways: (1) How common it was for a job not to be done the same way by multiple people, (2) the incredible dialog created to combine ideas and determine a better process, and (3) how the new work process was being followed by everyone weeks and months later.
Lean implementers will talk non-stop about the importance of employee engagement in everything that is done. There is good reason for this. Every problem has a countermeasure. Those countermeasures mean a work process WILL BE changed. It may be for one person or many. It may be a small, simple change or it may be a large, complex change. But there will be a change to the standardized work.
Getting people involved early helps to expedite adoption of the new process and helps to ensure adherence.
- Working with employees to create standardized work is critical to creating adoption and adherence to the new process
- It is extremely common that no one does the same job, the same way and standardized work is needed
- Standardized work is the foundation of improvement because it provides a baseline AND it DRIVES EMPLOYEE ENGAGEMENT.
Working for the automotive supplier, I had moved from industrial engineer to program manager and now into the lean group. The lean group comprised of just myself and one other, Joe Wilson who has contributed here at Beyond Lean.
One of our first assignments was to implement a plant-wide kanban system in 4 weeks. It was a mandate that came down from our Vice President to all the plants. In that short time, Joe and I had to learn about kanban, devise a system, create a simulation to teach 500 employees and implement the system.
Good thing we were young and full of energy back then, because I don’t know how we did it but we did. We developed kanban cards by color signifying which department the card need to return to in order to place the order for more parts. We then created a very simple Lego simulation. The simulation was good for 5-6 people at a time and allowed each person to be hands in order to create better learning. We also used the exact kanban card that we were going to put on the shop floor for the simulation so the employees got used to seeing them and could give feedback on them. We then trained 500 people on the simulation, five at a time across three shifts.
One rule we stressed the employees was, “Do NOT violate the kanban!” If you don’t have a card, you don’t build. Even if you know cards are in the internal customer’s hand and haven’t been brought to you. That holds the customer accountable for “ordering” the parts from the supplying department.
Everyone was ready to go live on our due date and we nailed it. Not saying there weren’t problems, but we hit the date and people were trying their best to follow the new procedures.
Then it happened. Our go-live date was mid-June. If you are familiar with the auto industry, everyone shuts down for retooling for a week or two around July 4th. So one week into the kanban system, our management was telling everyone to violate the kanban in order to build the bank of parts for the few shipments we have during the two week shutdown.
Yep. Violate the Number 1 Rule right out of the gate. It caused Joe and I a lot of rework after shutdown to get the kanban system back up and running. In the end, it worked well thanks to the great employees and the management support, but the false start didn’t help.
- Building the bank of parts for shutdown was the correct thing to do at July 4th. What we need to be more conscious of is when we start something. It would have been better to start the kanban training after shutdown so we didn’t have the false start and have management telling everyone to violate the number 1 rule right off the bat.
- We made kanban cards that were small. 4 inches x 3 inches or so. Cards were get dropped and lost quite a bit. It is better to make larger kanban cards (8 inches x 6 inches). It is harder to lose these because they are easier to see and don’t fit in pockets without folding a laminated card.
- Creating a simulation that allowed everyone to be hands-on and using the actual kanban card from the floor really helped to create learning, understanding and good dialogue with the employees.
Recently, my wife had an experience with supplier that wasn’t focused on us as a customer and it created great waste for the supplier.
The shop was low on a particular candle that we buy from a local handmade supplier. The product is great and it sells really well. My wife emailed the owner to order more candles. In the email, she asked if the owner could send a list of spring related scents as we phase out the holiday related scents, so we could pick out what we think our customers would like.
We didn’t hear from the owner for about a week or more. Then the owner shows up with the candles we ordered plus three new spring scents. We didn’t like one of the scents. We said we wouldn’t take that one and discussed other possibilities to choose from. A different scent was picked and a few days later the owner returned with the new scent.
When the issue of not responding was brought up to the owner, the reply was they were so concerned that we needed the candles right away that they just made them as quick as possible and brought them over. My wife explained that we don’t need things immediately, especially after the holidays and if there is ever any question to just ask.
The owner wanted to please us, but didn’t focus on what was truly important to us which is the scent selection. The owner ended up causing waste of defects/rework (making new candles she hadn’t made), waiting (us waiting longer to get the order filled) and transportation (driving to our store twice).
Have you or your company ever rushed a product or service to market because YOU thought that was what the customer needed and then if failed? What were you focused on?
If you aren’t sure what your customer needs are…ask. Be clear and focus on what they need, not what you think they need.
Note: I want to give a big shout out to Dan Markovitz, author of A Factory of One. It is an excellent book on how to gain efficiency in your personal work. Dan outlines things you can do in regards to email that will help with efficiency. While I have been doing almost all of the suggestions for a few years now, Dan did have one suggestion that was new to me and helped me with a problem I was having. I have implemented the suggestion and it works very well. I will point it out below.
On with the blog post.
We all want to improve our efficiency and free up time. In my personal work and in observation, one of the biggest culprits of causing inefficiencies is email. Here are three things I have done to help eliminate some of the distractions and inefficiencies email causes me.
1. Turn off Email Notifications: In Outlook, I have turned off all notifications of incoming email. Nothing popping up in the bottom corner showing a new email has arrived.
Result: When I am working on something I don’t catch the notification out the corner of my eye distracting me causing the back of my mind to have to know what the email was about. I stay focused on my work and can finish what I was doing.
On my phone, I have turned off the lights, sound and vibration of new email notification. There are two reasons: 1) if I am in a meeting and it is making noise or vibrating it is distracting me and others from the meeting and 2) if I am working at my desk is acts the same as the Outlook notification as it beeps or vibrates or flashes on my desk next to me.
Results: I am not distracted by incoming emails at all during meetings or while working at my desk.
2. Open Mail Software to Calendar: This was the new suggestion I found in Dan’s book. Thanks, Dan! When I open Outlook, it opens to my calendar. Not my Inbox! Most mornings, I have a quick email I thought of on the way into work that I have to send when I get in, but I was getting distracted by waiting email in my inbox. I might even forget to send the original email I went to write.
Results: I am able to send an email from the calendar view by selecting New Items –> Email Message from the menu at top. I always finish the email I intended to send out and I am not distracted by the other messages in my inbox. I don’t check email first thing in the morning and get off on the email tangent. I am able to complete something off my personal kanban board before checking email. I feel more productive and less distracted.
3. Use the 4D’s: I have been doing this for a few years, but never had a name for it until I read Dan’s book. When I decide I have time to process my emails I do one of four things: 1) Do it: reply back if it is a short reply or completed the action if it is less than 5 minutes, 2) Delegate it: delegate the work to someone that can help, 3) Designate it: for me this means if it is a larger task I add it to my personal kanban board or 4) Delete it: I have read it and don’t need it.
Results: My inbox is not cluttered with messages that I lose. I know what I have to process when I go into my inbox. I don’t loose track of requests made of me via email.
One last thing. Just because someone emails you doesn’t mean you have to read and respond immediately so don’t feel like you have to be hovering over your email waiting for it. If the person needs an immediate response, they can call. That is what a phone is for. We all have one in our pockets nowadays. Note: I do know some jobs require constant monitoring of email, like an order processor.
How have your improved your efficiency with your email practices?
I spent about a year working as an Industrial Engineer at Guardian before I got on opportunity to move into the Program Manager position. In this role, I was responsible for managing every engineering change that came through the facility. That could be a new paint color, new components or even a complete redesign with tool modifications. This covered over 5,000 part numbers and at least 10 customers.
Not only was there the external customers, but there were the internal customers. I had to work with the corporate design engineers and product managers as well as the facility’s engineers and senior staff. I had to make sure we were still profitable with the changes. It was a lot more difficult than I had anticipated. This is where I learned how to listen to customers wants and combine them with our capabilities.
Being focused on the customer and delivering what they would like does not mean bending over backwards and just caving to every demand they have. It means have a respectful relationship and working together to achieve the desired outcome. Sometimes it was easy. They customer would want a new paint color. I would work with the paint supplier to get the color developed, tested and approved. A pretty standard process and well within our capability.
Sometimes it was much more difficult. One customer wanted their grille of their flagship vehicle to have a “smoked chrome” look like it did in Japan. The look was very popular and they wanted to carry it over to the U.S. The issue was the paint they used in Japan was not legal in the U.S. because of the amount of VOCs. I worked with a team that sat down with the customer and understood what the “smoked chrome” look they were trying to achieve. It took over six months of development with our paint supplier and our process engineers to get the desired look.
All along the way the customer understood the effort we were going through and how complicated it was to get the desired look. Because of this, they agreed to pay a much higher than standard price for the grille. More importantly, a trust and a relationship had grown between our companies. One of respect and understanding. Our efforts to give the customer what they wanted but stay within our facilities capabilities made us a preferred supplier. Nothing was as complicated as that moving forward but when changes where needed, the customer took the approach of “this is what we are looking for. What can you do?”
It was a great lesson in serving the customer without bending on what your purpose and capabilities are in a way that benefits everyone.
- When working directly with the external customer, you must keep in mind your capabilities and core strengths and help deliver within those parameters. It can create some creativity.
- Must focus on the external customer first but you can’t forget the internal customer as well.
- Being firm, but reasonable can help garner trust and a strong relationship. When you give them everything not matter what it does to you, it doesn’t gain respect but one of dominance by the customer
A friend and fellow blogger, Tony Ferraro reached out to ask me to take a quick survey on lean. It took me 3 minutes to complete. In doing so, I thought it would be great if the Beyond Lean readers could help Tony as well. The survey will take less than five minutes of your time. He is going to share the results on his blog at Creative Supply.
Here is the link to the survey: Tony’s Survey
Thanks for your participation.
My time at Thomson Consumer Electronics came to an abrupt end as the company went from 2,000 people in the U.S. to 250 people in a years time. I got a job with Guardian Automotive. The facility I was hired into specialized in exterior plastic trim. Guardian’s customers included almost everyone during the five years I was there: GM, Ford, Chrysler, Toyota, Honda, Nissan, Harley-Davidson, BMW, International and Freightliner to name a few.
The first few months was very frustrating. My manager and I were trying to make process changes that made since to us in order to reduce WIP. We wanted to move assembly next to the paint lines so there was no paint inventory, but people fought this at every turn.
Then a big change happened. Guardian got a new VP of manufacturing and he brought in his director of lean. We were going to be a lean company. After years of studying Shingo and using lean tools, this was the first time I had heard the term “lean”.
Everyone got pulled off-site for an intro to lean and a hands-on balloon simulation showing pull vs push. During the simulation, I leaned over to my manager and whispered, “This is what we have been trying to do for months with the paint lines.” I was anxious to see how things would go now. The couple hour simulation was the extent of our lean training. We were told to “go do”.
Talk about ‘deer in the headlights’ after that. No real training and being told to “go be lean”.
The first thing my manager and I did was re-establish the idea of connecting the assembly area to the paint lines. We discussed it with the plant manager and how it would be like the balloon simulation. We had his support and were able to complete the work within a few weeks.
Over the next few years, the facility became a lean playground for myself, Joe Wilson (who also blogs on Beyond Lean), and our manager. We learned something, tried it, screwed it up, fixed it and made huge progress.
Our time was a huge success in that the plant went from $500k in the red on $120 million sales to $8.5 million in the black on $90 million sales in three years. But it was a huge failure as well. We had phenomenal support to make the changes we did, but we didn’t change the leadership’s thinking. After we all left the plant was back in the red in about a year.
I don’t say that to too our own horn, but as a lesson in how important it is to change people’s thinking and behaviors in order to sustain the change.
I will be diving deeper into my experiences at Guardian moving forward.
- It is critical to not only have the support of leadership but to change their mindsets and behaviors in order to maintain the changes during a lean implementation
- Top down support makes an enormous difference in the work you can accomplish and the time to accomplish it
In a previous post, I talked about learning a software package that allows people to model and simulate a factory before making any physical changes. After the building of the factory that failed to implement pull, my role was to model current production lines when changes were recommended and to model the proposed model lines for new products.
One of the new production lines that I modeled was for a new television technology. The Liquid Crystal on Silicone (LCoS) television sets. This technology was about a year ahead of LCD TVs and was cheaper to produce. It was only 18 inches deep which is laughable now but at the time was about half as deep as typical big scree projection TVs.
The manufacturing engineers came up with a design for the new production line. By all means, it looked like a line that would meet the production needs and on paper the number of stations and equipment needed looked perfect.
The model was built and simulated with actual unit testing data as well as workstation operation times. It was a great thing we did, because we could have had another fiasco if we didn’t.
The simulation showed the back of the line being severely starved and the front of the line being overwhelmed. The line would have produced at only 66% of the rate it needed to run. The animation of the simulation showed how many TV sets were being kicked out into the rework loop and the backup it caused. It was a perfect example of the Markov Chain in real-life.
We were able to redesign the production line to be 33% shorter and have the ability to produce at a rate high enough to meet demand and allow for growth with no investment.
This was a great example of fail fast, fail cheap. It took less than a month to build the simulation, test, analyze, rework and get approved. The company saved thousands of dollars and the product went to market on time.
I know simulation software packages aren’t cheap, but it was cheaper than building the production line seeing the failure in real-life and then scrambling to fix it or build a second line.
How does your company fail fast, fail cheap?
- The value of prototyping and understanding before going full out is ALWAYS understated
- Simulating with cardboard boxes to computer software is an important part of making changes, especially big changes.
- Always better to fail early on with something that doesn’t cost much vs. finding the failure in full production mode. Doesn’t matter if it is a new marketing idea (test in an area) or manufacturing.