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News Feed for 18 November 2009 November 18, 2009

Posted by Jeff Fuchs in Uncategorized.
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The first few items below are particularly noteworthy, I think.  As the economy has put pressure on your organization, what type of lean leader have you been?  The post points to seven traits of a lean leader, that are especially important during a downturn, when leadership is most important.  For some, this may be a helpful tool to recalibrate and “find your leadership center.”

Want to see what Toyota’s Tsutsumi plant looks like?  There’s a whole raft of high-res pictures for all you lean weenies to pore over and pick apart.  Go nuts, guys.

The green innovations just keep coming.  I have pointed to a number of head-turning novelties that I hope make it to full commercial success. 

Enjoy these posts.  As usual, please post your feedback and thoughts.

Have a great Thanksgiving!

Until next time,

Jeff

Seven Essential Qualities of a Lean Leader November 18, 2009

Posted by Jeff Fuchs in leadership, lean.
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The current state of the economy has business owners scrambling to retain profits and cut costs. In such a risky environment, notes blogger Jon Miller over at Gemba Panta Rei, “I am sad to see even some avowed lean leaders turning away from the principles and qualities that make them not merely exceptional leaders but lean ones.” Mr. Miller has taken the time to pen an excellent article on the seven critical qualities for a lean leader to retain in a tough economy. The first letter of each of these qualities (e.g., Perspective, Responsibility, and Openness) amount to the acronym “PROFITS”.

Check out the article here.

“If it Doesn’t Improve, It Degrades” November 18, 2009

Posted by Jeff Fuchs in Lean Thinking.
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Kevin Meyer over at Evolving Excellence has taken to exploring misconceptions about Lean management and the Toyota experience. His blog takes a look at an article in Quality Digest that analyzes serious misconceptions about Lean production. The idea that standardized processes never degrade is what alarmed him the most. Toyota management’s success concerns targets, achievement and stabilization of that target, and standardization with the intent to reach the next target at once. Mr. Meyer explains quite rationally, “If it’s not improving, it’s degrading. Period.”

Check out the blog here, and the Quality Digest article here.

The Environmental Triumphs of Toyota’s Tsutsumi Plant November 18, 2009

Posted by Jeff Fuchs in automotive, green business, manufacturing.
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Toyota’s Tsutsumi factory in Japan is a marvel of green engineering.

Roofs covered with grass and solar panels. Through these green measures alone, the Toyota plant at Tsutsumi, Japan, generates 2000kW per hour, equal to 500 households, and saves 2,500 200-liter drums of oil. The assembly plant’s photo-catalytic paint-coated exterior breaks down airborne nitrogen and sulfur oxides to the equivalence of planting 2,000 trees. Equally impressive is the “comprehensive water recycling program [that] has led to a 50 per cent reduction in water discharge to the local river system. The water that is discharged from the plant is rigourously filtered so that it is five-times cleaner than the river itself.”

The article also highlights the efforts of Toyota employees and their families to plant trees, allow employees to dress more casually to cut down on air conditioning, and the creation of an incentive-based program designed to engender environmental stewardship by employees.

For the blog post, go here. For just a ridiculous amount of great pictures, go here.

Behavior Modification: Making it Fun November 18, 2009

Posted by Jeff Fuchs in Creativity & Innovation, Lean Thinking, change management.
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One of the biggest problems with process improvement is sustainment. One way to help make change stick is to make the new method rewarding and…well…FUN!

In these two videos, watch what happens when a set of stairs was converted to a giant piano keyboard.  If your goal was to increase people’s level of exercise and discourage the use of the escalator right next to the stairs, you’ve succeeded.  In the second clip, a sound effect machine was placed in a trashcan giving the effect of the sound of a freefalling object into the world’s deepest garbage receptacle. In one day, 72kg of garbage was collected in the outfitted trashcan, while normal trashcans nearby collected 41kg less.

As one comment points out, your interpretation of this concept need not be as quirky, but the idea is key: How can you make the new method of doing business more rewarding and fun than the old one?

Videos of both innovations were collected by Kevin Meyer here.

Reducing Interruptions and Improving Patient Safety November 18, 2009

Posted by Jeff Fuchs in 5S & Visual Management, Lean Thinking, healthcare.
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Simple interruptions can be dangerous. The Lean Blog’s Dan Markovitz points to research done at the University of California at San Francisco that shows even minor interruptions cost money –and lives. The study included nine San Francisco Bay Area hospitals and focused on the administering of drugs based on the reduction of interruptions.

Markovitz notes that “the Institute of Medicine estimates that errors in administering medication cause about 400,000 preventable injuries in hospitals and about $3.5 billion in extra medical costs each year.” Over 36 months, there was an 88% drop in errors when employees worked to reduce interruptions. The innovative ways in which nurses alerted others that they were administering drugs included visual indicators such as green vests and sashes, as well as a simple announcement that medications were being administered.

Read the article here.

Free Value Stream Mapping Fonts November 18, 2009

Posted by Jeff Fuchs in Lean Thinking.
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If you have ever wanted value stream mapping icons for PowerPoint or Word, here they are!

Value Stream Mapping is an important part of Lean management. But too often people focus on the mapping rather than the method the mapping is supposed to engender. Personally, I encourage lean practitioners to stick to paper and pencil to improve group understanding and lower everyone’s dependence on the computer as a crude and marginally effective collaborative tool.  Even these days, however, the Lean Enterprise Institute recognizes the need for an occasional PowerPoint, and has icon images on their website.  Jon Miller at Gemba Panta Rei explains the use and potential benefits of the free lean fonts. The fonts, he claims, returns emphasis to the method rather than the map.

Check out the discussion here and the download site here.

Rethinking Lean: Beyond the Shop Floor November 18, 2009

Posted by Jeff Fuchs in healthcare, lean office.
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Rethinking Lean CoverOnce the domain of manufacturing, lean has migrated far beyond the shop floor, transforming service organizations and innovation efforts.  The principles of waste elimination, worker involvement and continuous improvement haven’t changed, though, and the results are still impressive.  In this special report, experts from Wharton and The Boston Consulting Group look at how lean is transforming health care, R&D and finance.

Download the report here.

Lowering the Supply Chain’s Carbon Footprint November 18, 2009

Posted by Jeff Fuchs in green business.
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Although scientists and analysts disagree over global warming, a consensus can be found with respect to good stewardship of the environment. In an article at IndustryWeek, the environmental impact of a company’s supply and logistics are revealed through the use of a new plan: the ICON-SCM Supply Chain Planning solution. The solution takes into account consumer demand for environmentally-conscious products and businesses. Based on a “best-case-scenario” plan, the solution involves emission planning capabilities, consideration of “environmental consequences of… sourcing, production and delivery planning”; and it also takes into account variables in terms of manufacturing locations, shipment methods, and frequencies.

Check out the article here.

Exec from Seattle Children’s Hospital on Lean Healthcare November 18, 2009

Posted by Jeff Fuchs in Lean Thinking, healthcare.
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With the nation talking about improving healthcare and the healthcare insurance system, Mark Graban over at Lean Blog has posted a review of an article that appeared in the Washington Post. Using a Lean model, Seattle’s Children’s Hospital has made encouraging and substantial improvements. They have, for example, reduced risks of infection by reducing the number of days patients are on ventilators by 26% and saved $2.5 million in supplies in their first year of Lean use. Their success demonstrates the integral part Lean can play in adding to the healthcare debate.

Check out the Lean Blog post here, and the Washington Post article here.

Ford Uses “Skunk Works” to Develop New Engine November 18, 2009

Posted by Jeff Fuchs in automotive, product development.
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Like all big companies, Ford has a strict product-development hierarchy.  Most times it works well, other times a different approach is required.

A “Skunk Works” is an entirely separate and autonomous development team that can move quickly, unencumbered by the rules and restrictions of a typical, integrated development process.

Recently, Ford used the Skunk Works approach for the creation of the new Scorpion engine.  The team went offsite with little contact from higher-ups. A handful of rules and creative freedom allowed the development of the heavy-duty engine in record time.

Read more here.

Who Says Lean Training Can’t Be Fun? Not Volvo November 18, 2009

Posted by Jeff Fuchs in Lean Thinking.
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volvoThe Volvo Group has helped to develop a computer game to teach the principles of lean production. Players of the game can see how different changes impact efficiency and profitability. Volvo reports results indicating that serious gaming is an effective complement to training at work.

Players can switch from scheduled production to customer-order-steered production, test different layouts, invest in new equipment, and immediately see how this affected efficiency and profitability.

Read more on the Society of Manufacturing Engineers Lean Directions e-newsletter here.

Would You Feel Safe Driving Across a Recycled Plastic Bridge? November 18, 2009

Posted by Jeff Fuchs in green business, new products and technologies.
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The U.S. Army recently announced that it is constructing two bridges out of recycled plastic. And apparently, the bridges are strong enough to carry tanks.

tankonbridgeThe bridges, scheduled to be built as part of a $957,000 contract with Axion International Holdings, will replace old wooden bridges at Fort Eustis in Virginia. Both structures’ railroad cross-ties will be made completely out of consumer and industrial plastic waste, and the 40- and 80-foot bridges will have a high-load rating of 130 tons.

The company claims that a bridge made from recycled plastic is 40% lighter and 25% to 30% cheaper than traditional bridges. Axion’s bridges are also less energy-intensive than wood or steel models, and they don’t need to be painted.

Read more here.

Manufacturers Still Have Job Openings Despite Unemployment November 18, 2009

Posted by Jeff Fuchs in economy, manufacturing.
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Manufacturers have unfilled job openings for high-skilled workers, according to a study by Deloitte, The Manufacturing Institute and Oracle.

The study found that “almost one-third of companies reported some level of shortages.” Companies are “having difficulty finding skilled production workers, scientists, and engineers.” The study also “found that manufacturers aren’t working to find these types of workers, or are depending on largely ineffective traditional approaches to managing and developing their employees.”

Mark Tomlinson, executive director and general manager of the Society of Manufacturing Engineers says that “manufacturers are looking for employees who are the opposite of the stereotypical factory worker doing repetitive, assembly line work. They are in need of 21st century workers with specialized technical training such as machinists, operators and technicians.”

Read more here.

Researchers See Biodegradable Electronics That Dissolve After Use November 18, 2009

Posted by Jeff Fuchs in green business, new products and technologies.
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Device---Day-235_tcm18-167325The British Royal Society of Chemistry reported that, “Compost bins of the future could contain biodegradable electronic circuits,” US researchers suggest. Stanford University scientists Christopher Bettinger and Zhenan Bao “set out to fabricate a biodegradable and biocompatible transistor. For two of the device’s components — the substrate and the dielectric — the researchers selected biodegradable polymers that have been approved for medical use by the US regulatory authorities.”

Read more here.

How We Work Now: Seven Twists On The Home Office November 18, 2009

Posted by Jeff Fuchs in Workplace Design, lean office, personal productivity.
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With millions of people working from home in the United States now, the need for home offices has never been greater. But space, construction permits, and utilities often plague the home-based entrepreneur. It is upon these problems that Fast Company has seized the initiative by putting together a collection of innovative and well-designed home office ideas. From the completely customizable L.O.F.T. workstation, to the Office Pod, to the Trunk Station, Fast Company has assembled seven unique home office solutions.

What will your home office look like in 10 years?

Check out the ideas here.

Shared Creativity Key to the New Definition of “Work” November 18, 2009

Posted by Jeff Fuchs in Creativity & Innovation, team development.
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Jeff Klein, CEO of Cause Alliance Marketing, is interviewed on the importance of creativity in the new paradigm of work: personal, meaningful, and part of an integrated life. Klein notes that collaboration fosters creativity when common causes and objectives also speak to individual interests. Allowing for creativity and adaptability, and recognizing the limits of individual knowledge, allow for other ideas and perspectives to move a project along. The idea is to have the openness to be able to adapt to changing circumstances and co-create with others.

For the interview, go here.

New Manufacturing Process Could Cut Costs, Save Weight November 18, 2009

Posted by Jeff Fuchs in manufacturing, new products and technologies.
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Additive Layer Manufacturing (ALM) “dramatically cuts the weight of structural parts” by replacing cast or forged items with “components built from metallic powder that is sintered into layers by laser.” Jean Botti, the head technology at EADS, “says ALM has great weight-saving potential in aircraft and will also cut manufacturing costs by reducing material waste. As much as 90% of the material needed to make a forged component is machined away to reach the final shape, compared with as little as 5% with ALM.”

Read more here.

Study Cautions Silver Nanoparticles’ Environmental Impact November 18, 2009

Posted by Jeff Fuchs in green business, new products and technologies.
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Nanotechnology promises great benefits, but its ecological effects are poorly understood.  The rapid proliferation of nanotechnology can potentially present long-lasting and unanticipated effects.  Recently, plasticware and clothing items have been imbedded with nanoparticulate silver to retard bacterial growth. 

The New York Times recently reported that “When it comes to killing bacteria, fungi and the like,” silver ions are very “effective antimicrobial agents.” Now, there are “hundreds of consumer products that contain small amounts” silver, “in the form of nanoparticles that release ions slowly over time,” which, for instance, “include “socks, whose silver nanoparticles help control odor. But socks and other antimicrobial textile products need to be laundered, which raises the possibility that some of the silver may end up in the wastewater.” As a result, there are concerns “that silver may kill beneficial bacteria and other small organisms.”

A recent Swiss study “found large variations in the amount of silver released in the first washing,” and suggested “that mechanical stress in the washing machine was responsible for most of the release.” The researchers say further studies are needed to determine particles’ “precise composition and how they behave once they end up in wastewater.”

Read more here.

A Silver Bullet in Silver Ink? November 18, 2009

Posted by Jeff Fuchs in manufacturing, new products and technologies.
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Printable electronics may be the key to cutting out the expensive cost of anything requiring circuits and circuit systems. Xerox is developing a low-temperature, low-cost silver ink that literally allows for the possibility of printing electrical circuits. Silver ink and the ability to print circuits like you would on any inkjet printer would drastically reduce –perhaps eliminating –the need for the much more costly method of utilizing silicon to create circuits.

Integrated circuits require three parts to work: a semiconductor, a conductor, and a dielectric element. The use of silver ink provides a valuable option to print a conductor, and by using silver ink, Xerox has the ability to print all three parts for a circuit – so we’re not just talking about printing the trace patterns on a circuit board, but the semiconductor components, as well!

Check out the post here.

Innovation at the San Diego Zoo Saves $$$ November 18, 2009

Posted by Jeff Fuchs in Creativity & Innovation, economy.
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Nonprofit organizations are consistently confronted with financial woes. For the San Diego Zoo, those problems include the accumulation of revenue in order to fund initiatives dealing with conservation and educational research as well as maintaining the zoo itself. Even with 4.5 million visitors, $200 million in annual revenues, and being able to show a $13 million operating profit, the San Diego Zoo found that it could not sustain itself on its current path.  So it turned to innovation and opportunity mapping in order to focus on three specific targets for growth, including strength and credibility, conservation relevance through connecting people to conservation, and conservation leadership. The article at BusinessWeek has an excellent analysis of the creation and breakdown of San Diego Zoo’s opportunity map, as well as the strategic aims it is pursuing.

Check out the article here.

IdeaPaint: Turn Your Entire Office Into a Whiteboard October 30, 2009

Posted by Jeff Fuchs in new products and technologies, personal productivity.
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IdeaPaintNow, you just *KNOW* I’m going to do this.

IdeaPaint is a paint that turns any paintable surface into a dry-erase board.

Besides being able to brainstorm on almost every inch of your office, the paint is half the cost of whiteboard and better-performing–you can leave marks up indefinitely and they won’t stain the wall.  For the green wonks out there, you should also note that one other benefit is that you’re not incurring all the carbon involved in manufacturing and shipping a whiteboard.

Read FastCompany’s write up here, which includes a video demo of the product.

Generator in Montgomery County, MD Turns Plastic Waste into Oil October 30, 2009

Posted by Jeff Fuchs in green business, new products and technologies.
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oil generatorThe ground-breaking Envion Oil Generator (EOG) gave its first public performance at the Montgomery County Solid Waste Transfer Station in Derwood, Maryland recently. The EOG can be fed almost any petroleum-based waste plastic and will convert it into synthetic light to medium oil for less than USD$10 per barrel. As with crude oil, the synthetic oil can then be processed into commercial fuels or even back into plastic.

Read more here.

New ‘Green’ Concrete Delivers Win-Win for Industry and the Planet October 30, 2009

Posted by Jeff Fuchs in green business, new products and technologies.
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Concrete is the most prevalent building material on the planet, but it does come at a price – around 5-8 percent of all human-generated atmospheric CO2 comes from the concrete industry. A culprit is Portland cement, the binding agent in concrete. Production of Portland cement is currently exceeding 2.6 billion tons per year worldwide and growing at 5 percent annually.

A greener alternative, inorganic polymer concrete (geopolymer), utilizes ‘fly ash’, one of the most abundant industrial by-products on earth, as a substitute for Portland cement.

Geopolymer concrete has a number of benefits. It has the potential to substantially curb CO2 emissions. It can also produce a more durable infrastructure capable of lasting hundreds of years, instead of tens. And by utilizing the fly ash, it can conserve hundreds of thousands of acres currently used for disposal of coal combustion products, and protect our water ways from fly ash ‘contamination’, too.

Read more here.

Uncovering Steve Jobs’ Presentation Secrets October 30, 2009

Posted by Jeff Fuchs in personal productivity.
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001_jobs_bookSteve Jobs does not sell computers; he sells an experience. The same holds true for his presentations that are meant to inform, educate, and entertain. An Apple presentation has all the elements of a great theatrical production—a great script, heroes and villains, stage props, breathtaking visuals, and one moment that makes the price of admission well worth it. Business Week’s Carmine Gallo recently wrote a book about Jobs’ presentation style.  Here he reveals the five elements of every Steve Jobs presentation. Incorporate these elements into your own presentations to sell your product or ideas the Steve Jobs way.

Read the five elements here.