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News Feed Update for 3 February 2010 February 3, 2010

Posted by Jeff Fuchs in Uncategorized.
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This group of articles has some great stuff to check out.

If anyone else is following the latest auto industry news, Toyota’s recent problems are splashed across the headlines.  However, there are festering problems at GM that are not getting very much attention.  Read the article on General Motors below and what our government appears to be requiring GM to do.  Not very lean, is it?

There are a couple very good articles here about change management, standard work, and the role of the leader.  These are critical topics to lean change agents.  I hope you enjoy them and find them useful.

As usual, there are also some tidbits on green business, healthcare, and new technologies that have great potential to change our lives.

Until next time, enjoy

Jeff

U.S. Companies Competing With China Using Lean February 3, 2010

Posted by Jeff Fuchs in Lean Thinking.
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Lean leaders know that cheap labor isn’t everything, especially when the interests of consumers have to be taken into account and responsiveness towards them is critical. According to the Delaware Valley Industrial Resource Center, due to the economic recession and competition from China, an estimated 60% of U.S. businesses have gone lean. To what extent they are truly “lean” is uncertain, notes Mark Graban at Lean Blog. But the point remains the same: In order to compete with labor-cheap China, U.S. companies are strongly advised to go lean.

Check out Mark’s post here.

A Reuter’s article on the topic is here.

How to Change a Company’s Culture February 3, 2010

Posted by Jeff Fuchs in culture, leadership, workforce.
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FastCompany gave Jigsaw CEO and co-founder Jim Fowler just thirty seconds to explain how a company can change its culture. His advice?

  1. Eliminate anyone poisoning the well.
  2. Lead from the front.
  3. Don’t shove the new culture down employees’ throats

Check out the video here.

GM’s Dangerously Naïve Owners February 3, 2010

Posted by Jeff Fuchs in Lean Thinking, automotive, economy, government.
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Critics of the Obama administration’s takeover of General Motors, and the subsequent stocking of GM with politically-appointed and inexperienced leaders now have more concrete evidence to their opposition of such moves. GM is going to be running a third shift on a permanent basis. In other words, the assembly lines will never stop moving. Ever.

Why?

According to the article,

 

The Obama administration auto task force that oversaw GM’s reorganization last spring was startled to learn that the industry standard for plants to be considered at 100% capacity was two shifts working about 250 days a year. In recommending that the government invest about $50 billion in GM, the task force urged the company to strive toward operating at 120% capacity by traditional standards.

 

The article goes on to bolster critics of the plan:

 

But industry manufacturing experts are skeptical, noting that the federal task force had limited automotive experience. “Do those guys understand the business?” asked Ron Harbour, whose Harbour Report is a widely followed analysis of auto-plant efficiency.

 

Running continuously means there is no time for cleaning, repairing, restocking, maintenance, and other necessary and helpful tasks conducted during downtime. This is a common error of traditional accounting, writes Kevin Meyer at EvolvingExcellence.  “Traditional accounting creates the desire to fill unused capacity in order to absorb overhead, depreciation, and other indirect costs. Usually regardless of whether demand actually exists for that capacity,” he writes.

And the Obama administration is hard-pressed by critics –and the American taxpayer –to make up for its $50 billion investment in GM. But overproduction of cars, hiring third shifts, and leaving no time for improvement are dangerous, non-lean, and counterproductive moves.

Check out Kevin Meyer’s analysis here.

Five Change Management Errors that Make You Wish You’d Read this Article Sooner February 3, 2010

Posted by Jeff Fuchs in change management, leadership.
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Jon Miller, over at Gemba Panta Rei, has written an interesting piece on five common errors made in change management. This is especially important when Mr. Miller reveals that Harvard professor and writer John Kotter has found that one-third of all change management efforts fail. Mr. Miller also quotes a 2005 study that reveals a scant 5% of companies are happy with their changes. So what are the common errors?  They involve “stakeholder maps”, methods versus principles focus, overlooking passive resistance, leaving people “in the trough”, and humility.

This is a great article for all change leaders.  Read the details in Mr. Miller’s excellent article here.

Communication Tips for Lean Leaders February 3, 2010

Posted by Jeff Fuchs in leadership, workforce.
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Liz Guthridge, guest-writing at the Lean Blog, analyzed a communications study to draw from it five important communications tips for lean leaders:

  1. Leaders must understand that communication is part of their job. 
  2. Don’t overwhelm people with unnecessary information.
  3. Meet face-to-face, and meet regularly.
  4. Be accountable.
  5. Encourage people to speak truthfully.

Check out the post here.

What’s the ROI of a 5S Program? February 3, 2010

Posted by Jeff Fuchs in 5S & Visual Management.
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Jon Miller at Gemba Panta Rei was recently asked, “What is the ROI (return on investment) of a 5S program?” There is an ROI to 5S, but it depends on varying factors. Was 5S implemented as part of a larger lean effort or a stand-alone management initiative? The question itself poses problems, because as Mr. Miller points out, it’s a very vague and general question. But when implementing 5S, “the scope and purpose should be clearly defined upfront, and that includes any expected benefits.”

Check out the Gemba Panta Rei article here.

Pinewood Derby Cars, Standard Work, and Training February 3, 2010

Posted by Jeff Fuchs in Lean Thinking, Standard Work.
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Scott Meruna over at the Lean is Good blog, has his hands full. His six-year old son had to construct a pinewood derby car for Boy Scouts, and it got Mr. Meruna thinking about standard work. In particular, safety, ergonomics, and mistake-proofing were components that stood out. But “standard work does not eliminate the need for training,” Mr. Meruna notes.

Check out Mr. Meruna’s lively and refreshing post here.

The Business Case for Carbon Management February 3, 2010

Posted by Jeff Fuchs in green business.
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Businesses aren’t going green just because it has become fashionable, or because they wish to comply with regulations or standards, or even because green is what the customer wants. Instead, most businesses are looking to managing their carbon footprint because it also figures into cost-savings, and a healthier bottom line.

Sustainability and environmental initiatives fall into two broad categories. Short-term tactical actions, one of the two categories, aim at waste reduction, use of energy, and carbon emissions reductions. Longer term strategic actions aim at the overall carbon footprint of a company. The benefits derived from these goals include cost-savings, new business opportunities, and competitive advantage. Indeed, according to an article at Industry Week, “78% of the respondents identified sustainability initiatives as, “very important to somewhat important to their overall business strategy,” with 87% reporting such initiatives as, “important to their future growth plans.””

Check out the Industry Week article here.

Keen to be Lean in Healthcare February 3, 2010

Posted by Jeff Fuchs in Lean Thinking, healthcare.
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Washington can’t fix the astronomical costs of healthcare, according to Jamie Flinchbaugh. He points out that lean in healthcare tends to be directed only towards cost reduction. That is a frequent mistake, he asserts. Healthcare costs are one of the major driving deficiencies of the Big Three auto manufacturers. But rather than focus solely on the cost in terms of quantity, perhaps attention should be paid towards improving quality. And it turns out that improved patient care quality actually reduces costs,” writes Mr. Flinchbaugh. He argues that good intentions and good training are not enough; and that “bad processes beat good people every single time”:

“Regardless of what happens in Washington, I know this. We have a lot of work to do to design, manage, and improve the work of the healthcare professionals. And Washington can’t do that for all the physicians, nurses, assistants, pharmacists, technicians, and administrators that suffer from bad processes.”

 

Check out Jamie’s insightful article here.

New Nano-Material Could Lead to Self-Washing Windows and Solar Panels February 3, 2010

Posted by Jeff Fuchs in green business, new products and technologies.
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While attempting to find a cure for Alzheimer’s Disease, researchers at the University of Tel Aviv discovered a new nanomaterial, one capable of repelling dust and water, and could prove to be a self-cleaning coating for windows:

Using peptides – short polymers formed from the linking of amino acids – the researchers from Tel Aviv University (TAU) found a novel way to control the atoms and molecules of peptides so that they “grow” to resemble small forests of grass. The short peptides, which are simple and inexpensive to produce, were used to create self-assembling nano-tubules in a vacuum under high temperatures.

Indeed, at one-billionth of a meter in size, the nano-tubules are able to withstand extreme heat as well as water. A coating for windows that utilizes the nano-tubules would eliminate the need for window-washing, and could also be used on solar panels. Dust accumulation on solar panels makes them 30% less efficient; a nano-tubule coating could easily remedy the situation.

Check out the Gizmag article here.

A Breakthrough for Hydrogen Storage? February 3, 2010

Posted by Jeff Fuchs in new products and technologies.
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The explosive nature of hydrogen had always prevented its full-scale commercialization. But now, according to an article as BusinessWeek, a breakthrough in hydrogen storage could lead to the long-awaited marketing. Called capillary arrays, bundles of thin, strong tubes of glass contain the hydrogen designated for use. It’s possible that this form of hydrogen energy storage could replace conventional laptop and cell phone batteries, among other things. The final issue, however, once tests are successfully completed, is how to find cheap, or even affordable sources of hydrogen.

Check out the BusinessWeek article  here.

Tiny Glitter-Sized Photovoltaic Cells Could Revolutionize Solar Power February 3, 2010

Posted by Jeff Fuchs in green business.
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Hunters, hikers, and military personnel may no longer be hampered by dead batteries and failed equipment. Indeed, the clothing that they wear may actually allow them to recharge failed devices and keep batteries charged. But that would require extraordinarily small photovoltaic cells.

And that is precisely what scientists from Sandia National Laboratories have developed. Measuring in at 14 to 20 micrometers thick –and a human hair is about 70 micrometers thick –the new photovoltaic cells are made from a crystalline silicone. The Sandia team has identified over 20 benefits to the new cells over traditionally-sized and produced cells, including better performance, more efficiencies, and possibly reduced cost. Greg Nielson, Sandia’s lead investigator noted that “Eventually units could be mass-produced and wrapped around unusual shapes for building-integrated solar, tents and maybe even clothing,”

The new cells are a leap forward in renewable energy technology, and if mass production can be achieved at a good cost, will revolutionize the energy industry.

Check out the Gizmag article here.

Job Satisfaction at Record Lows: Will it Ever Be Satisfied? February 3, 2010

Posted by Jeff Fuchs in workforce.
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Through economic boom and bust, job satisfaction continues to decline in the United States. In 1987, the first year the Conference Board charted workplace satisfaction, 61% of people reported being satisfied with their jobs. Today, only 45% of people are happy with their jobs. The causes vary, and more than likely include worker noninvolvement, discontentedness to “sit in their cubicles and churn out the work asked of them”, and so on. Perhaps, muses Joe McKendrick at SmartPlanet, “there’s entrepreneurial yearnings that eventually manifest themselves as fresh ideas, new startups, and new products.” Whatever the cause of worker dissatisfaction, it should be embraced as a challenge.

Check out Mr. McKendrick’s analysis of the Conference Board report here.

North America Still Strong for Manufacturing February 3, 2010

Posted by Jeff Fuchs in manufacturing, workforce.
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The 2003 decision of Texas Instruments to build a silicon chip factory in Richardson, Texas was the result of a checklist of fifty items. These included such factors as intellectual property protection, logistics, water, power, earthquakes, and even typhoons. Plus, the new site, only a few miles from another TI factory, meant synergies on parts and consumables. A dash of incentives from the University of Texas didn’t hurt, either.

One of the deciding factors to keep Texas Instruments in, well, Texas, was local engineering talent. Experienced talent in China gets turned over fast. A good startup team was needed.  Where better than the United States?

Indeed, contrary to politicking and common assumptions, manufacturing is still growing in the United States, albeit not at previous rates. “U.S. manufacturing capacity surged by 44 percent during the boom years of 1994 to 1999, while the economy expanded by 26 percent,” writes Rob Spiegel at Automation World. But between 2002 to 2007, capacity rose by 5%, while the economy expanded by 12%. In 2007, according to the United Nations, the United States still commanded 20 percent of world manufacturing, set against China’s 12 percent.

Disillusionment with China is setting in, based on things like unionization, intellectual property theft, and serious quality deficiencies. Add to that the United States worker safety leadership and the low value dollar, and the potential for exporting manufacturing jobs to the United States is high. The trick is reasserting the dominance of the dollar and maintaining our manufacturing edge.

Check out the Automation World article here.

A Pop-Culture PDCA Cycle? February 3, 2010

Posted by Jeff Fuchs in Lean Thinking.
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Mark Graban over at Lean Blog had a few interesting thoughts about the Jay Leno/Conan O’Brien late night television war that erupted recently. Mr. Graban described the NBC debacle using the Plan-Do-Check-Act cycle. The plan was to move Leno to 10 P.M. and put Conan on at 11:35 P.M., perhaps to gain a wider audience and a younger demographic. Then NBC implemented the plan. The ratings (the Check portion) were horrible. NBC reacted (the Act portion) and moved Jay back to 11:35 and pushed Conan back to 12:35.

I had to comment on Mark’s blog, that if NBC were a truly lean organization, and had properly implemented PDCA, then an examination of why the scheduling rearrangement failed should have been conducted. How does NBC prevent recurrence of a future scheduling misstep like this?

Check out Mark’s post here.

Outsourcing Point/Counterpoint February 3, 2010

Posted by Jeff Fuchs in supply chain.
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Outsourcing does not always ensure a healthy bottom-line. According to Dr. Lowell Yarusso at Industry Week, this can be averted by avoiding “two critical errors that frequently result in value leakage across the entire portfolio of outsourced good and services”.

The first error is described as “Fire, Aim, Ready-Decision Making”. Companies have a tendency to rush into it, believing it will give them an immediate competitive edge or that quick outsourcing will bring about quick profits. Careful planning is essential.

The second error is described as “Don’t Confuse Me with Facts Decision Making”. In companies that push outsourcing as the best strategy, the inherent danger is that management may reject any analysis whatsoever that outsourcing may not be successful. Because of this, “Knowing what results are expected, assumptions, data collection, analysis, and conclusions may be skewed to support a recommendation to proceed.”

Some of the most critical factors that need to be fully understood when outsourcing are laid out in Dr. Yarusso’s article. These include “Specific vs. General Competencies,” in which include the continually changing process of where and when to outsource; “Leading vs. Following,” which includes looking at both short term and long term values, recognizing that entering an emerging field increases risk-taking, and not entering an emerging field may prove costly.

Third, there is “Total Cost of Ownership vs. Fully Loaded Costs” which examines the indirect causes that can have consequences on profit based on outsourcing. Outsourcing cost savings are often offset by hidden costs “that have not been allocated to the outsourcing effort.”

Finally, there is “Cost Arbitrage vs. Value Arbitrage.” The traditional advantage of outsourcing rests in taking advantage of the difference of –usually – labor cost in two different markets. However, before the commitment is made to outsource to a particular locale, “it is absolutely critical that future market potential in that locale be included in the equation. The so called Optimal Zone, where cost savings are high and local market potential is high, should be the long-term goal of any outsourcing strategy.”

Companies seeking to outsource should bear all of these factors in mind. The most jarring cause of poor returns on outsourcing, it would seem, are the indirect costs related to outsourcing.

Check out the Industry Week article here.

Manufacturing Rebounding, says Industry Group February 3, 2010

Posted by Jeff Fuchs in economy, manufacturing.
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It’s no secret that the United States needs to increase its manufacturing base, and that the country is currently facing a difficult economic climate. But according to the Manufacturer’s Alliance/MAPI, a recovery in the manufacturing sector may just be in sight. Their composite index for December 2009 rose to 57% from the September 2009 report of 38%. This is also the first time in six quarters that the index hit 50%.

Among the other notable highlights of the report that Manufacturer’s Alliance/MAPI published, the export orders index increased to 47% from September’s index of 19%; the backlogs index rose from 16% in September to 36% in December. Research and development came in at 66%, well above the September index of 49%. The profit margin index, although below 50%, nevertheless increased to 38% from 22%. These signs are clearly encouraging, and with more investment in America’s manufacturing sector, can only get better.

For the Industry Week article about the report, go here.

The Mintzberg Debate on Executive Bonuses December 30, 2009

Posted by Jeff Fuchs in economy, leadership, workforce.
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One of the most scrutinized causes of the financial crisis in 2008 is executive compensation and bonuses. An analysys at the Evolving Excellence blog of a Wall Street Journal column by Henry Mintzberg spells out a solution clearly and succinctly: Scrap bonuses altogether.

Esteemed social scientist Henry Mintzberg believes that bonuses aren’t necessarily the best way to elicit outstanding business performance. In fact, handing out bonuses can be poison to a company because it places success or failure squarely on the shoulders of a few people. That pushes aside unity and teamwork. Mr. Mintzberg notes:

“A robust enterprise is not a collection of ‘human resources’; it’s a community of human beings. All kinds of people are responsible for its performance. Focusing on a few—indeed, only one, who may have parachuted into the most senior post from the outside—just discourages everyone else in the company.”

A common defense of the bonus system maintains that without bonuses, you won’t get the right person in the CEO’s office. But Mr. Mintzberg asserts that you may get the wrong person in the CEO office with the bonus system:

“At the worst, you get a self-centered narcissist. At the best, you get someone who is willing to be singled out from everyone else by virtue of the compensation plan. Is this any way to build community within an enterprise, even to foster the very sense of enterprise that is so fundamental to economic strength?”

Only engaging employees at every level will the business be a productive community. But do executive bonuses have to be done away with in order to bring together a workforce?

Adam Zak thinks demonizing the executive bonus isn’t the answer. After all, paid-vacation days, base salaries, perks and other benefits might well also be targeted and condemned. Community or not, Mr. Zak makes the point that each individual will be contributing something different to the company, of various values.

If we eliminate bonuses from the compensation package we’re still going to need some way of differentiating the value each individual contributes to the organization. Perhaps this can be accomplished via the salary mechanism, but this just implies a much wider range of salaries. And salaries present the disadvantage of being, typically, fixed for the duration of a year or so.”

How to fix that?

“…we could make salaries variable, adjusting them periodically based on someone’s perception and interpretation of the value contribution for each individual. But if we get to that stage I’m thinking that all we’ve really accomplished is simply engage in word play, creating a fixed and ‘variable’ component for salary. Sounds like a bonus to me.”

Instead of eliminating bonuses –after all, they might well be inseparable from a more demanding job –Mr. Zak suggests “a more accurate and transparent way of measuring and valuing the contribution each individual… makes to the organization, and then rewarding her for that contribution. This is the real challenge which needs to be addressed and, unfortunately, Mr. Mintzberg offers us no guidance in this area.”

 

To read the Evolving Excellence analysis, go here.

To read Adam Zak’s analysis, go here.

To read Mr. Mintzberg’s WSJ editorial, go here.

 

Editorial: All Small Manufacturers Need a Lifeline December 30, 2009

Posted by Jeff Fuchs in economy, manufacturing.
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In a letter to the editor of the Detroit Free Press on Christmas Eve, Mark Tomlinson, executive director and general manager of the Society of Manufacturing Engineers, wrote, “The White House’s proposal to add another $5 billion in job-producing tax credits for manufacturers of environmental technology is a nice holiday gift for those who are invited to the party. But what’s under the tree for the 300,000 small manufacturers in industries such as medical devices, aerospace, defense and transportation? They must feel a bit like Tiny Tim standing out in the cold, because they can’t get the support and credit they need to survive.”

Read the full letter here.

Planning “End Of Life” for Electronics Could Help Manufacturers December 30, 2009

Posted by Jeff Fuchs in green business, manufacturing.
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The Chicago Tribune recently reported on Harrison Kim, an assistant professor in the University of Illinois. Kim studied the lifecycles of electronic gadgets and the associated costs, “and found that the time to think about…’end of life’ issues is before the small electronics are even designed.” Specifically, Kim “analyzed how design differences affect product recovery and determined that manufacturers are losing money by not reusing components.” Fewer than 5 percent of retired phones “are recycled or reused.” Kim said, “These are profits currently neglected.” One way manufacturers could benefit, he said, is by designing products that were modular. Such products would also “appeal to the environmentally-savvy consumer.”

Read more here.

How Green is Wal-Mart’s Drive-Through Window? December 30, 2009

Posted by Jeff Fuchs in green business.
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Wal-Mart customers on the outskirts of Chicago, instead of waiting for online orders to arrive at home, can now pick up their orders at a drive-through window. It is an experiment Wal-Mart is trying out, but how green is the idea? Ariel Schwartz, writing at Fast Company, notes that getting a CD shipped to your house instead of going out to buy a CD cuts down on carbon emissions.

That remains the case when ordering the CD online and picking it up at the store. But that isn’t the innovation –the drive-through line is. “Instead of wasting gas by hunting for a parking spot, shutting off the car, and turning it back on to leave, shoppers can zip through the drive-through, presumably only idling for a minute or two,” writes Ms. Schwartz. “That might not sound like big carbon savings, but when millions of Wal-Mart shoppers are taken into account it adds up quickly.”

Check out the article here.

Why Small Manufacturers are Going Green December 30, 2009

Posted by Jeff Fuchs in green business, manufacturing.
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With the debate around global warming heating up in recent years, companies have modified their processes and products to address consumer concerns over environmental practices. One of the improvements many small manufacturers are making is the investment in clean energy. Whether they are utilizing clean energy or producing the means to make clean energy, like the company Shuttleworth in Indiana, going green is in. The fact that even smaller companies are doing what they can to go green is indicative of the consumer and political environment. Because of that environment, green manufacturing offers a silver lining to an otherwise overcast economy.

For the BusinessWeek article, go here.

The Lean Ratio December 30, 2009

Posted by Jeff Fuchs in Lean Thinking, strategy.
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Measuring things seems inescapable, especially in a world that places so much emphasis on numbers and counting. Measuring lean productiveness, specifically, is best expressed as a percentage according to Bill Waddell over at Evolving Excellence. That is the measure of value added expenses to total expenses. Mr. Waddell explains:

If the business spent $20,000, for instance, and $12,000 of it was on value adding things while the rest was on management, supervision, material handling, inspection and generally pushing paper around, the Lean Ratio would be 60%; or it could be expressed as 3:2 if you like looking at numbers that way better.

However, Mr. Waddell also explains that comparing the leanness of companies to one another is useless; what really matters is that each company, individually, is continually improving. The idea is to continually improve the useful ways in which money is spent.

Check out Mr. Waddell’s post here.

“Flexing” Hospital Staff is No Route for Improvement December 30, 2009

Posted by Jeff Fuchs in Lean Thinking, workforce.
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Mark Graban over at Lean Blog has shared his experiences working in the healthcare field, and was surprised to learn that hospitals will use “flexing” –sending home workers when an expected workload doesn’t come in.

Staff workers can contribute to the medical environment every bit as much as professionals, Mr. Graban notes. Flexed workers tend to feel less important and not as valued as professionals. Yet the idea of flexing presupposes that medical staff can do nothing to improve their work environment. Mr. Graban writes,

Toyota never sends hourly workers home early when there are parts shortages or other situations that mean there’s no direct work to do. Supervisors engage their brains in improvement activities. Why can’t we do the same with highly skilled nurses?”

Mr. Graban also relates that overstaffing can be a problem, yet, there has to be some time for improvement –and that requires input from staff.

To see Mr. Graban’s post, go here