Lean Thoughts


This week’s Issue | 06/07/2020

Living with Covid has meant traditional processes are being constantly modified then adjusted as everyone attempt to make life feel as normal as possible or at least how they remember normal … but in some cases these new process changes are actually wonderful new experiences that I personally hope will stay forever.  Hence this week I decided to write the content about be afraid that you do not succumb to the 30 inch view and the power of as a leader being the observer …

As the use of masks are being encouraged or even mandated how do you know if your mask is truly effective?  Try the “Candle Test” … attach your mask to your face as prescribed and then light a match, candle or lighter and the n through your mask attempt to blow out the flame … if you can, it is time to replace your mask, if you cant you are good to go with an effective mask.   Wear you mask if you are a kind human being … it is not only meant to protect you but also to protect others from you … let us be kind to one and other!!!

Enjoy the other Covid advantage as restaurants are allowed to expand patio dining … the weather is wonderful so who would want to sit and eat inside anyway.   ENJOY !!!



This week’s Issue | 22/06/2020

Work Breakdown analysis was the foundation that enabled Ford to create the assembly line … this destroyed the myth that batch work was best or “one person, one complete product” … Now with Covid and the non-negotiable factor of inconsistent employee attendance … the use of “Cellular Process” will be a powerful attribute to your operation.  Concerns about Physical Distancing are mute … since you can design the cell to operate in one of 2 primary manners … 1) material is moved from station to station or … 2) people and material move from station to station.

Simple engineering will support Physical Distancing and the power of cells allows you to flex capacity to market need quickly.  And … the concern about tribal knowledge limiting productivity is eliminated since you have no room to accommodate tribal knowledge and in many cases visual connection is better than verbal connection to improve consistent quality and productivity.   Plus these methodologies work awesome in office and administrative processes …

A quick introduction to cellular is in this week’s newsletter … or contact us for design help  or process refinement.



This week’s Issue | 15/06/2020

One common thing as a result of Covid … is that everyone everywhere are changing their processes.  Changing existing processes is primarily due to averting a reoccurring problem and these changes are naturally done using “Job Skill and Experience” with inputs these days of regulatory guidance.  These are reactionary gestures and few pause to use or review with a rational process to determine value or the ultimate impact on cost. For example these days if you sell Lexan … it is better than winning a lottery and guess what no 2 sneeze shields are being designed the same … costs have sky-rocketed but the need has become a must if as a retailer you want to stay in business …

But crisis averted you need to take pause and reflect using a rational process to verify or modify your process changes.   A great tenant is to capture the “Voice of the Customer” using “Critical To” (CT) trees and then quickly mapping your new processes using Enterprise Value Stream Mapping (EVSM) and then validate your map (EVSM) against your VOC to insure that it is delivering the intended results and within your cost targets.

Most important is that every time you make a process change provides you with an opportunity to improve customer satisfaction while reducing costs and improving velocity … so pause, reflect, document and adjust …  This week some past tips but still pertinent on how to create your Value Stream Map ….



This week’s Issue | 07/06/2020

Contamination control is not new … although it appears to have taken on a whole new level of importance these days.  It does make one wonder how bad were organization’s concerns about our wellbeing before the outbreak of Covid. As the frequency of sanitation practices increases organizations are adding components into employee’s work spaces … but are they easily accessible ?  because if not they will not be used … of course the use needs to be supported with a strong procedure and protocol in order for the change to be effective.   There is CONTAMINATION and then there is CROSS-CONTAMINATION so as you adjust procedure you should be adding color codes to your cleaning supplies to prevent CROSS-CONTAMINATION … cleaning tools to be used for equipment should not be the same as those to protect or clean floors … but all of this together will automatically lead to work-space organization or 5S … so this week we review some basic tips to better work space organization as a reminder …



This week’s Issue | 29/05/2020

As we transition through the Covid-19 pandemic … adaptability has become a new important leadership trait.  Unfortunately we cannot look in the rear-view mirror to forecast our new normal … so we need to cognizant not to alter our processes with PTF (Permanent Temporary Fixes) and no real need to totally invent new processes like sanitation … al retail has to do is to look at their OEM food manufacturers and use standard GMP (Good Manufacturing Practices) as a baseline starting point … Ultimately, this is a great time in a state of perceived crisis while exercising adaptability to design new robust processes using Lean Methodologies … while focusing on protecting people without adding time or cost to the process …



This week’s Issue | 18/05/2020

Every Organization is currently changing or adjusting their processes as a result of Covid-19 … which is both a reaction but also a great opportunity.  Being a process-weanie … I have now started to judge and rate these process changes to see who is the most compliant and most effective … while others are just applying a veneer approach thinking they are fooling the customer that they are protected.  Very similar to deployments of Lean Methodologies we have witnessed … good intentions but failure to think it through … Consistent is that all stores have a gate keeper which seems usually to be a new hire … with a failure to understand that this is your “Vice-President of First Impressions” … think about it … people are standing in a line waiting for access and this golden opportunity to enhance customer engagement is being ignored …

We have discussed pausing to develop your VOC (Voice of the Customer) .. so this week we re-printed a reminder of who the customer really is … and customers can make choices and now a new element of choice has been added to the equation …  Is yours a compliance addition or an opportunity of adding protection and dignity to your customer?



This week’s Issue | 11/05/2020

Last week we challenged you to find a balance within your processes between the “Voice of the Customer” (VOC) and adjusting your processes to support the “Voice of Regulation” (VOR) … but as we witnessed this week as organizations react and Jump to Solution … they decide to drop some of their basics which during these transitionary time can be the most powerful assistant to you and your organization.  We are on the cusp of being forced to re-develop our processes and re-evaluate our value propositions … WHAT AN OPPORTUNITY !!!   this can be a very positive opportunity to significantly re-establish your identity … so don’t lose the opportunity or designate it as an obstacle … pause, think and redeploy could result in you reassuming or becoming your industry leader.  Good thing is that everyone has been presented with the same challenge of potential opportunity …

Become innovative while retaining your basics and stay true to the principals that initially brought you to the dance floor … and of course as you reinvent yourself feel to connect with us to be part of your team as your “outside eyes”



This week’s Issue | 04/05/2020

Without knowing it, businesses are starting to develop the “New Normal”

 

Any successful business originates by listening to the Voice-of-the-Customer (VOC) … but recently the customer definition has changed from the consumer to regulators looking to prevent the spread of Covid-19.  These activities have been prioritized in the business models with a “consistency of purpose” but an “inconsistency of process”.  I fully understand and support the prevention measure to mitigate the spread of the virus but these knee-jerk process changes will most likely become the new expectations of consumers after the pandemic subsides.  Capturing the Voice-of-the-Customer (VOC) is very important to the success of any business … but in these times organizations need to pause and capture a balanced approach for both the consumers and the regulators … so we explore “how” in this week’s newsletter.  Struggling ??? … contact us for help to develop your VOC.

 

When I speak of “inconsistency of process” … I enter my local “No Frills” the door sentry provides me with a cart, wipes down the handles another touch points of the cart, sanitizes my hands before I am allowed a metered entry to the store … across town at Zehr’s I can grab my own cart but must at my option sanitize my hands and cart handle … Then off I go to COSTCO where people are lined up with their carts in the rain and no sanitation stations in sight … and now Longo’s has announced that starting Monday I can only shop in the store if I wear a face mask … which they are happy to sell me one … so in which scenario do you feel the safest to shop?

 

Just imagine if all of them had paused to capture a balanced VOC what the results would be?  People forget all about Subliminal Messaging and the potential lasting effects …

 



This week’s Issue | 27/04/2020

They say the only constant in life is “CHANGE” and these days everyone is definitely being impacted.  Most of the change impacting us these days is mostly reactionary rooted based on skill, experience and intuition.  In this case many of the changes are going to permanently mold our lives going forward … so it really is a journey of change … with many of the changes involving process which at one point will be reviewed to define if it is “truly value-add” … the journey has definitely started which means that it has formed a baseline for many tweaks and changes to come … either as process enhancements or further compliance to process.  What is missing in visibility is the new incurred costs associated with change and how much more is the consumer willing to pay for personal protection?

Since all organizations have started a journey of process change … let us take pause to review what a “Lean Journey” needs to encompass … so a pause, read and review could be beneficial by reading this week’s newsletter.  Sometimes history becomes the new frontier … so it is a humble re-print of a former newsletter but very pertinent for today.

For certain, as the weather improves here in North America complying to the new requests are just going to increase our personal challenge to comply.



This week’s Issue | 20/04/2020

JUMP TO SOLUTION !!!  This is the normal human solution when impacted by an unscheduled “Disturbance to Flow” which definitely Covid-19 has created on many businesses.  This has resulted in many changed processes to prevent the spread of the virus … but at what cost?  Making decisions based on “Brain Storming” using skill and experience can provide a solution but not necessarily the most cost effective.  I have witnessed personally the effect of Continuous Improvement in our current retail environment … the initially reaction was to dramatically increase clean and Sanitization (our planes are actually now clean inside) but as some implemented “cough shields” they have slowly migrated across several other retail locations.

Although it is not part of your brain’s muscle memory before jumping to solution pause and use a formal methodology to plan your process change before implementation which will most likely be both expensive and subject to ongoing adjustment.  Typically I would suggest doing an EVSM (Enterprise Value Stream Map) but perhaps a team activity creating a “Fish-Bone” diagram will confirm your thoughts or add new ideas.  This week we review the use of an Ishikawa diagram.


Lean Thoughts

30 Inch View — you cannot LEAD by DOING !!

This week’s Issue | 06/07/2020 Living with Covid has meant traditional processes are being constantly modified then adjusted as everyone attempt to make life feel as normal as possible or at least how they remember normal … but in some

Cellular will work despite Covid-19

This week’s Issue | 22/06/2020 Work Breakdown analysis was the foundation that enabled Ford to create the assembly line … this destroyed the myth that batch work was best or “one person, one complete product” … Now with Covid and

Deming’s PDCA and Value Stream Mapping

This week’s Issue | 15/06/2020 One common thing as a result of Covid … is that everyone everywhere are changing their processes.  Changing existing processes is primarily due to averting a reoccurring problem and these changes are naturally done using

PROCESS — Workplace Organization … doing it right!

This week’s Issue | 07/06/2020 Contamination control is not new … although it appears to have taken on a whole new level of importance these days.  It does make one wonder how bad were organization’s concerns about our wellbeing before

Basic 5S+1 pricipals

This week’s Issue | 29/05/2020 As we transition through the Covid-19 pandemic … adaptability has become a new important leadership trait.  Unfortunately we cannot look in the rear-view mirror to forecast our new normal … so we need to cognizant

Who is the CUSTOMER?

This week’s Issue | 18/05/2020 Every Organization is currently changing or adjusting their processes as a result of Covid-19 … which is both a reaction but also a great opportunity.  Being a process-weanie … I have now started to judge

RETAIN YOUR BASICS — although you may need to adjust

This week’s Issue | 11/05/2020 Last week we challenged you to find a balance within your processes between the “Voice of the Customer” (VOC) and adjusting your processes to support the “Voice of Regulation” (VOR) … but as we witnessed

Voice Of the Customer (VOC)

This week’s Issue | 04/05/2020 Without knowing it, businesses are starting to develop the “New Normal”   Any successful business originates by listening to the Voice-of-the-Customer (VOC) … but recently the customer definition has changed from the consumer to regulators looking to

Process Change is a journey

This week’s Issue | 27/04/2020 They say the only constant in life is “CHANGE” and these days everyone is definitely being impacted.  Most of the change impacting us these days is mostly reactionary rooted based on skill, experience and intuition. 

Fish-Bone

This week’s Issue | 20/04/2020 JUMP TO SOLUTION !!!  This is the normal human solution when impacted by an unscheduled “Disturbance to Flow” which definitely Covid-19 has created on many businesses.  This has resulted in many changed processes to prevent

Lean Thoughts

30 Inch View — you cannot LEAD by DOING !!

This week’s Issue | 06/07/2020 Living with Covid has meant traditional processes are being constantly modified then adjusted as everyone attempt to make life feel as normal as possible or at least how they remember normal … but in some

Cellular will work despite Covid-19

This week’s Issue | 22/06/2020 Work Breakdown analysis was the foundation that enabled Ford to create the assembly line … this destroyed the myth that batch work was best or “one person, one complete product” … Now with Covid and

Deming’s PDCA and Value Stream Mapping

This week’s Issue | 15/06/2020 One common thing as a result of Covid … is that everyone everywhere are changing their processes.  Changing existing processes is primarily due to averting a reoccurring problem and these changes are naturally done using

PROCESS — Workplace Organization … doing it right!

This week’s Issue | 07/06/2020 Contamination control is not new … although it appears to have taken on a whole new level of importance these days.  It does make one wonder how bad were organization’s concerns about our wellbeing before

Basic 5S+1 pricipals

This week’s Issue | 29/05/2020 As we transition through the Covid-19 pandemic … adaptability has become a new important leadership trait.  Unfortunately we cannot look in the rear-view mirror to forecast our new normal … so we need to cognizant

Who is the CUSTOMER?

This week’s Issue | 18/05/2020 Every Organization is currently changing or adjusting their processes as a result of Covid-19 … which is both a reaction but also a great opportunity.  Being a process-weanie … I have now started to judge

RETAIN YOUR BASICS — although you may need to adjust

This week’s Issue | 11/05/2020 Last week we challenged you to find a balance within your processes between the “Voice of the Customer” (VOC) and adjusting your processes to support the “Voice of Regulation” (VOR) … but as we witnessed

Voice Of the Customer (VOC)

This week’s Issue | 04/05/2020 Without knowing it, businesses are starting to develop the “New Normal”   Any successful business originates by listening to the Voice-of-the-Customer (VOC) … but recently the customer definition has changed from the consumer to regulators looking to

Process Change is a journey

This week’s Issue | 27/04/2020 They say the only constant in life is “CHANGE” and these days everyone is definitely being impacted.  Most of the change impacting us these days is mostly reactionary rooted based on skill, experience and intuition. 

Fish-Bone

This week’s Issue | 20/04/2020 JUMP TO SOLUTION !!!  This is the normal human solution when impacted by an unscheduled “Disturbance to Flow” which definitely Covid-19 has created on many businesses.  This has resulted in many changed processes to prevent