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Auto Union Chief Presses for Trade Reform January 26, 2009

Posted by Jeff Fuchs in automotive, supply chain.
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United Auto Workers president Ron Gettelfinger has taken aim recently at free trade policies as a factor in the problems that beset the American automobile industry.aleqm5gv3rhtvqyton9mjoqalbi_xxyxvg

“We must take action to fix our broken trading system,” he said in remarks prepared for an automotive conference.  “We can no longer afford to have the most open market in the world, while other countries use currency manipulation and non-tariff barriers to keep out US-made products.”  Gettlefinger tempered his message by saying that “the UAW is not opposed to fair trade, but it’s time to recognize that so-called ‘free trade’ is a fiction.”Gettelfinger noted further that the deficit in automotive trade alone is expected to hit 109 billion dollars and the US has an automotive trade imbalance with every one of its major trading partners, including Britain, which has a small automotive industry.

I am not quite sure that Gettlefinger is placing appropriate emphasis on the issues here.  If we have a automotive trade deficit with every single one of our automotive trade partners, does this imply that every single one of them – including the British – are manipulating their currencies to create a competitive disadvantage for U.S. companies?

Toyotas and other non-American cars are assembled in the U.S. (mostly in the southeast) and use the North American supply chain for most of their parts, like the Detroit Three.  How does currency manipulation of the yen or the euro figure into the competitive strength of non-U.S. players in the U.S. auto market?

Certainly, currency issues are a central factor in trade balance.  However, Mr. Gettlefinger’s calculus is a bit oversimplified.  For a more nuanced example of the factors at play, take a look at the recent Business Week article, The 65 mpg Ford the U.S. Can’t Have, to see some of the confounding reasons why we can’t seem to get a car made here that is double the typical available average new car gas mileage.  By attacking trade policy, Mr. Gettlefinger draws attention away from labor components of new car costs.

Gettelfinger did say, though, that his UAW is willing to consider concessions like those spelled out in the terms of the federal bridge loans for GM and Chrysler. However, before the UAW agrees to any kind of wage concessions, he wants to be able to examine the books of Japanese companies such as Toyota, Honda and Nissan to how they calculate labor costs. 

I can’t argue with a desire for an apples-to-apples comparison, especially if the government sets competitive benchmarks for the Detroit Three against Japanese producers.  It has been well established, however, that the initial quality ratings and assembly times of Japanese versus U.S. automobiles have roughly reached parity in recent years, so the need for Uncle Sam and Gettlefinger to get into Toyota’s books are largely unnecessary, in my mind.  The real issues are company overhead, development expense, and employee benefits.

Read Mr. Gettlefinger’s extended comments here.

What are your thoughts on the plight of the U.S. auto industry, the UAW, or trade policy?

At the Whiteboard: Setting SMART Goals January 26, 2009

Posted by Jeff Fuchs in personal productivity.
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BNET recently released a short video (under 4 minutes) that describes how to set SMART goals.

Now folks, this is pretty much Management 101 stuff.  However, for all you Lean Thinkers out there, I will tell you that I have found many, MANY instances where the five points of SMART goals are violated when it comes to kaizen events.  Take a look at this video and think about them in terms of the objectives that were set for you (or that you set as a leader, process owner, or sponsor) in your kaizen events. 

Has it ever happened that you got to your kaizen out-brief and the person who chartered your kaizen or the leadership team in the audience ripped your solutions apart?  If it has happened to you, remember how demoralizing that was for you and your team?  Very often, train wrecks like this happen because they are engineered to happen: the train is sabotaged even before it leaves the station! 

I have seen this happen when the solutions the team came back with are not the ones the leaders had expected – or wanted.  The root cause?  The problem statement or kaizen charter was not specific or measurable: SMART guidelines were not followed.

See the video here.

By the way, if you like those UPS whiteboard commercials, you will appreciate this series of videos.  Very lean. 

Have you ever sat through a meeting where the person holding the whiteboard pen scrawls sentences of text?  How productive did you feel sitting there …. while …. he …. wrote … out …. every …. single …. word?  Or how about when the stuff left on the board is like something a three-year old left behind?  What does it mean?  The motion of the pen certainly meant something in the context of that single instant of conversation, but what does it mean five hours – or five minutes – after the guy sits down?

The UPS commercials and these BNET spots show how your whiteboard in compelling ways.  The visuals are simple, supplement your verbal presentation, and help structure your content.  If you like this type of stuff, check out books like Back of the Napkin.

VIBCO Award Video January 26, 2009

Posted by Jeff Fuchs in Lean Thinking, manufacturing.
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At the Northeast Shingo Prize Conference this fall, I had the opportunity to meet some of the folks at VIBCO.  What a great crew!  This video was produced to introduce the company after they won a Rhode Island State award.  From a leadership, culture, education, and involvement standpoint, this video shows that VIBCO clearly “gets it”.  Manufacturers: you may see some things that VIBCO does that you do not.  But, for the most part, they look very similar to many manufacturers.  It’s not what they have, but how they think and work, that makes them an award-winning lean company.

See their YouTube video here.

States Seek Efficiency Through Lean Techniques January 26, 2009

Posted by Jeff Fuchs in Lean Thinking, government.
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More state governments are applying continuous improvement techniques based on lean thinking to cut costs, improve service and make employees more productive. For example, Ohio has cut the time it takes to get a complaint decided at the Bureau of Workers’ Compensation from an average of 142 days to 34. Iowa has cut the time needed to obtain an air quality construction permit from 62 days to six. Massachusetts has cut the time to get a death certificate from 95 days to five. “It has taken off like wildfire around the country,” said Teresa Hay McMahon, performance results director in Iowa, where kaizen was first used in state government about five years ago.Read this extensive article dtailing many of the gains.

Six Sigma in Government: Focusing on the Customer January 26, 2009

Posted by Jeff Fuchs in government, six sigma.
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Six Sigma, with its emphasis in many cases on hard, current-year results, is often not associated with government agencies and their processes. One reason is that a government’s mission is as much about providing services to the public and other stakeholders as it is about cutting costs and realizing efficiencies. In fact, there is frequently tension between these two aims.On one hand, government agencies want to provide comprehensive services. On the other, they want to be seen as lean and efficient, using tax payers’ money wisely. Likewise, the public and other stakeholders want – and indeed demand – effective services from government agencies; however, tax increases are always unpopular, even when they are used to expand service levels. Therefore, Six Sigma professionals working in government agencies must shift their focus from financial savings, the primary goal of projects in the business world, and make added value for customers their first priority.

Read the full article here.

Relying on Memory Leads to Rework January 26, 2009

Posted by Jeff Fuchs in Lean Thinking, government.
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Mark Graban in the LeanBlog points to Chief Justice John Roberts’ flubbing of President-elect Obama’s swearing in as an overreliance on memory in lieu of a mistake-proofing checklist.  He has a good point.  Just as a pilot or (increasingly) as a medical doctor would rely on a checklist to avoid an error, Chief Justice Roberts could have used his note cards.  Now, just like having to “go around” on a landing or opening up the patient to retrieve a sponge, the oath of office had to be readministered.

Whatever you call it – poke-yoke, mistake-proofing, error-proofing, Justice-proofing – looks like a few billion people just saw a huge lean case study!

Read Mark’s deeper discussion and examples here.

Value Stream vs. Functional Organization Design January 26, 2009

Posted by Jeff Fuchs in Lean Thinking.
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To remove the conflicts between value-stream management and the traditional management found in a functionally organized company, Sunnen Products Company created a new organizational structure focused around value streams. The St. Louis-based machine builder decided to dedicate some resources to value streams while others are shared or remained at the corporate level to have consistent policy decision across the value streams. The story by LEI faculty member Bill Kerber includes a table and chart showing shared resources and the new reporting structure, respectively.

 

Read the article here.

Report: Getting More from Lean January 26, 2009

Posted by Jeff Fuchs in Lean Thinking, leadership.
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Executives interviewed for the report “Getting More from Lean” by The Boston Consulting Group said lean transformations are difficult to implement for a variety of reasons, including cultural resistance, lack of skills, poor knowledge of processes, and leadership problems. BCG identified seven important keys to implementing a successful lean conversion:

  • Sselect strategic, customer-centered projects
  • Think big, but start small
  • Involve everyone from top managers to line workers
  • Tailor your approach to your culture
  • Assign dedicated, experienced people
  • Use metrics to drive progress
  • Communicate, communicate, communicate

The report can be found here. (Published by The Boston Consulting Group, October 2008.)

Six Ways to Manage Leadership Stress January 26, 2009

Posted by Jeff Fuchs in leadership, work-life balance.
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Effective leaders know that stress can be a good thing. But stress can also be toxic, especially in the brutal economic environment we’re in. Article author John Ryan found that managing leadership stress comes down to a handful of critical elements: maintaining perspective, exercising, opening up, welcoming feedback, streamlining, and recharging.Read the full article here.

The Positive Business Manifesto – Hoshin Planning for Employee Engagement January 26, 2009

Posted by Jeff Fuchs in Lean Thinking, workforce.
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Adam Zak recently described the importance of respect for people in achieving lean enterprise goals.  Zak points out that even though lean leaders understand that positive leaders, positive work environments, and positive engaged employees produce positive results, few organizations actually create these conditions.

Zak points to the Positive Business Manifesto, written by Jon Gordon.  It does, indeed, have some excellent and inspiring points about achieving positivity in the workplace.

Read Adam Zak’s comments and link to the document here.

Corporate America, Swing Your Ax Wisely January 26, 2009

Posted by Jeff Fuchs in manufacturing.
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In December, IAC Interactive CEO Barry Diller told the crowd at the Reuters Media Summit, in effect, that if you’re making money, you shouldn’t be laying off huge numbers of employees to please an investor base that’s unlikely to be appeased in any case.Although the temptation is to slash expensive workforce in a downturn, being more prudent might be a business advantage long-term. For talented employees, the prospect of job security is one of the best reasons to join a big, publicly traded company. Take that incentive away, and you give smart, energetic people one more reason to join a startup or branch out on their own.

Read the full article here.

Who’s Keeping Score? January 26, 2009

Posted by Jeff Fuchs in supply chain.
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To keep up with how suppliers are performing, many manufacturers have started using “scorecards” to record statistics of their own. However, relatively few have done so in a way that actually generates much useful information, according to Sherry Gordon, president of the Value Chain Group, a supply management and performance excellence consultancy.”Everyone asks what KPIs should be on their scorecard, what everyone else is doing. But in reality, it comes down to what your company needs from the supply chain.”

Read the full article here.

Why So Many Minds Think Alike January 26, 2009

Posted by Jeff Fuchs in Creativity & Innovation, change management.
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Decades of research show people tend to go along with the majority view, even if that view is objectively incorrect. Now, scientists are supporting those theories with brain images.

Read the details hereart_brain_nih.

How Creative Thinking Can Help in the Downturn January 26, 2009

Posted by Jeff Fuchs in Creativity & Innovation.
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It doesn’t matter what the economic conditions are, better thinking is never a luxury. In fact, better thinking is an absolute necessity when times are hard, according to noted creativity expert Edward de Bono. de Bono is a prominent thinker in creativity circles.  This brief article serves to incentivize leaders to think laterally about their situation to improve their chances for survival and success.

Read the article here.

Toyota’s “Why Not” Website Invites Environmental Ideas January 26, 2009

Posted by Jeff Fuchs in Creativity & Innovation.
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The Innovation Weblog reports on Toyota’s recently launched website that encourages visitors to submit ideas for environmental innovations.  It also describes Toyota’s own efforts in these areas. Entitled “Why Not?” the site challenges visitors to make a difference in the world through their ideas.In addition to serving as an idea community, the website is also a contest portal. One person’s idea will be chosen as the winner; he or she will receive a week-long trip to and VIP plant tour of Toyota’s Kentucky facility as well as an invitation to meet with top innovators in New York City.

See the description here.

Obama Cites Lean Company as Example of How to Reinvent Manufacturing January 20, 2009

Posted by Jeff Fuchs in Lean Thinking, manufacturing.
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18496792_200x150obamaDeclaring that “we’ve started this year in the midst of a crisis unlike any we’ve seen in our lifetime,” President-elect Barack Obama on January 16th urged leaders of both political parties to adopt an American Recovery and Reinvestment plan that will, he said, “immediately jumpstart job creation and long-term growth.” Obama’s comments were made on site at Cardinal Fastener & Specialty Co. Inc., a manufacturer of precision fasteners used in the construction of wind turbines.Although Obama did not directly address lean manufacturing in his comments, Cardinal Fastener has instituted lean concepts based on the Toyota Production System since 1998. According to John Grabner, president of Cardinal Fastener as well as a consultant on lean thinking, Cardinal’s lean initiative has led to increased efficiencies, decreased costs, and better and faster service to its customers.

Read more in the full article here.

Toyota Taps Toyoda Family Member to Lead January 19, 2009

Posted by Jeff Fuchs in Lean Thinking.
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2008062551akio-toyodaOn January 12th, Toyota Motor Corp.’s senior board members selected as its next president Akio Toyoda, grandson of the company’s founder, people familiar with the matter said, putting a member of the founding family in the driver’s seat for the first time since 1995.  The 52-year-old Mr. Toyoda, known internally for aggressive management, faces the huge challenge of steering Toyota as plummeting global auto sales are expected to force the company into its first annual operating loss in 70 years. He also must prove to people in and outside the company that the family is competent to run it.

CEO of Arch Chemicals Inc. Leads National Association of Manufacturers January 19, 2009

Posted by Jeff Fuchs in manufacturing.
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Michael Campbell, the president and chief executive officer of Arch Chemicals Inc.of Norwalk, Conn., started a two-year term on January 1, 2009, as chairman of the board of directors of the National Association of Manufacturers (NAM), the nation’s largest industrial trade association.

Read about Campbell, Arch Chemicals, and Campbell’s plans here.

Building From the Basics January 19, 2009

Posted by Jeff Fuchs in Lean Thinking, Lean Tools & Techniques, six sigma.
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In his book, Total Quality Control, Kaoru Ishikawa described the seven basic tools of quality that could be used to solve 95% of a company’s problems. I teach these tools in my workshop on creativity and systematic problem-solving.  They are, indeed, at the bedrock of process improvement, whether you are a Six Sigma wonk or a Lean Weenie.  These tools are common knowledge, but they are not common practice.  In many of the kaizen events and six sigma projects I audit and mentor, these tools are often misapplied or missing altogether.  Get reacquainted with these essential tools to improve your process improvement efforts.

Read about the Seven Tools of Quality in Quality Progress here.

5S Still Gives Companies Fits January 19, 2009

Posted by Jeff Fuchs in 5S & Visual Management, Lean Thinking.
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Jamie Flinchbaugh of the Lean Learning Center answers a question on Bosch Rexroth’s lean page. One on 5S was recently posted in their latest email newsletter. You can read the question and answer on Mark Graban’s LeanBlog page. Most companies start with 5S because it’s simple. It may be simple, but that doesn’t mean it’s easy. In his reply, Flinchbaugh describes one of the most common problems with 5S: 5S that looks good, but functionally doesn’t work.  There’s looking pretty, and then there’s a stable, low-waste, visually managed work area that helps identify problems.  They are two different things.

Read the post here.

Just In Time — Lean You Can Believe In January 19, 2009

Posted by Jeff Fuchs in Lean Thinking.
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The economic recession is hitting every business hard – across the board. The question for every manufacturer whose doors are still open is: What can be done to stop the bleeding? IndustryWeek recently teamed with TBM Consulting on a study of global manufacturing trends in the U.S.,U.K., Germany, France, Mexico and Brazil. The majority of respondents ranked “cost pressures” as the biggest hurdle they have to face in 2009. Ken Koenemann, managing director in TBM’s Lean Value Chain Practice answers the key question: What should manufacturers be doing now that they’re not already doing?
“If you’re not already applying continuous improvement practices or LeanSigma in your operations, then you should in order to create competitive advantages and cost efficiencies,” Koenemann suggests. “If you are already implementing the principles and tools of the LeanSigma culture, then you should look at ways to accelerate its implementation throughout the organization.” As he points out, lean manufacturers are much stronger and better able to weather a downturn than their nonlean counterparts.

Read the full artcle here.

Lean Six Sigma: Contacts That Count January 19, 2009

Posted by Jeff Fuchs in Lean Thinking, healthcare, six sigma.
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Quality Progress magazine describes how a process improvement team within a health care support company used lean Six Sigma tools to improve member contact rates.  As a result of their efforts, the contact rate went up 65%, improving member outcomes and return on investment.  The effort earned the team a silver award in ASQ’s International Team Excellence competition.

Read the full article here.

Meeting of the Minds: Where Process and Discrete Manufacturing Converge January 19, 2009

Posted by Jeff Fuchs in Lean Thinking, manufacturing.
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What could a plant manager from a process manufacturer that makes yarns and fabrics for industrial applications possibly learn from an automaker such as Toyota? Conventional wisdom says companies should benchmark against similar industries to gain knowledge relevant to their operations. But as we’ve seen with businesses ranging from medical institutions to governmental agencies adopting lean principles, one industry may have best practices that can be tailored to fit a completely different work environment. The same goes for process and discrete manufacturers.Read more here.

Steven J. Spear, “Chasing the Rabbit” January 19, 2009

Posted by Jeff Fuchs in Lean Thinking.
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The latest installment of the LeanBlog Podcast is a discussion with Steven J. Spear. Spear is a Senior Researcher at MIT, a Senior Fellow at the Institute for Healthcare Improvement, and is the author of the new book, Chasing the Rabbit: How Market Leaders Outdistance the Competition and How Great Companies Can Catch Up and Win.  Mark Graban talks with Spear about how he started studying Toyota and his new book, which includes examples from many high-performing organizations in manufacturing, healthcare, and other industries.

Find the podcast here.

Training Budgets in a Down Economy January 19, 2009

Posted by Jeff Fuchs in workforce.
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Manufacturers are slashing the amount of money they spend to train their workers — 40% say they have cut training budgets because of the current economic climate.There are ways to control training spending and to keep training quality high. These include onsite training, seminars, online resources, formal schooling, and simulation software.

Read more about the alternatives here.