Posts Tagged ‘Flinchbaugh’

How to react when you find something out of place in 5S

Saturday, January 28th, 2012

Sustaining 5S is the hardest part. The average life of a 5S program is 1 year, and sustainability is the reason. So what behaviors should you exhibit to make it work?

Finding something out of place in the 5S’d area is not a sign that the system is broken. In fact, it’s a sign that it is working. It worked because you noticed it. You’ll never keep everything in place all the time. Unless it’s a serious violation, my first reaction to something is just to move it back where it belongs. Many people might disagree with that, because it’s an opportunity for coaching. But if you literally grab every opportunity to coach that you find, you’ll never leave the one area. Correcting it is the behavior you’d want from those in the area, so if the system tells you what to do, then just do it. That’s role modeling the behavior you want to see in others. If it is not straightforward, then ask an operator in the area what is the item, or where it belongs, or why it’s not in the right place. They are the ones who will best know. If needed, coaching can be provided. If it becomes a pattern, then it needs to be brought up with the supervisor in the area so that they can coach as well as hold accountable.

If you are on an audit, then the right first response is to the supervisor, because the audit is specifically focused on the process. You are surfacing issues about the system working when on an audit, so that is meant to facilitate the discussion with the supervisor in the area.

Furthermore, if all of these fail, then change the system. This means find a way to make the particular failure easier to do right, easier to spot when wrong, impossible to do, etc. We can’t always go back to coaching and reminders. Find some way to make the repeated failure no longer a problem.

What’s important about these behaviors is that they are widespread and consistent. This isn’t just for the manager immediately of the area in question. Anyone in management should be in the same page. Get other people who might be going through the area engaged, such as engineers and HR.

Promoting Employee Engagaement–A Cautionary Tale

Thursday, December 22nd, 2011

by Andy Carlino

Those of you who know me are aware that I have been slow to embrace the power and value of social media.  Fortunately my friend and partner, Jamie Flinchbaugh, has convinced me of the error of my ways.  This is my 1st foray into the blogosphere and I hope to be a valuable contributor. 

Although it is becoming less common, unfortunately it is still not uncommon to find employees, and even entire departments, unwilling to participate and contribute ideas or suggestions to improve their organization.  The reasons are wide and varied and often would take a psychiatrist’s couch to understand.  The following is a tale of an extremely important department in a company, we will call them AAA, that was not only unwilling to be engaged, they were downright militant about it.

They were a very mature workforce with many years of experience with a long history of employee engagement being unwelcomed and, in fact, discouraged.  The only requirement was “just get the work done”.  How efficiently or effectively you got the work done was not important.  Times have changed at AAA and so have the expectations.  Efficiency and effectiveness are now paramount and absolutely critical.  Unfortunately these employees are in an “entitled” environment and they are essentially employed for life unless they commit some significant egregious offense.  Little to nothing can be done to force performance improvement and professional “encouragement” was not working. 

A previous and proven method we have used to promote employee engagement and performance improvement in a difficult environment was to simply post real-time performance metrics at the point-of-activity.  In most cases we see a 3%-7% improvement in performance by posting the metrics. The thinking is that most of us want to know what the score is at any time and the metrics will stimulate the competitive and winning spirit in all of us.   So, of course, that was that was our solution at AAA.  Up went the metrics with the goal lines and the traditional and simple visual management technique of red, yellow and green color coded performance indicators.  The color coding made it easy for everyone, including the department employees, to recognize performance status.  We might as well have put a red cape in front of a raging bull. The reaction was a disaster.  What a mistake.  None of the metrics were even close to goal so they were obviously “all” red.  Not only was this not a motivator, it was a demotivator.  They were insulted and even more resistant to contributing and improving.  The cautionary tale is simple.  Regardless of how powerful or effective you think a simple lean tool/technique like color coded visual management indicators may be, never underestimate the power of the culture.  You too will experience the “unintended consequences” of acting without thinking.

We are trying to correct the mistake.  Still have metrics at the point-of-activity but they are only bar and trend charts.  No color coding, no goal lines.  Not sure if we can recover but the data suggests things aren’t any worse off than before and possibly getting better.  Time will tell.  I can tell you this, I don’t want to ever go through this experience again and hopefully you never will.

Engaging Through Daily Huddles

Tuesday, September 7th, 2010

Regardless of where you sit in the organizational hierarchy, daily huddles are a great tool for any team to create engagement, alignment, surface problems, and more. Andy Carlino and Jamie Flinchbaugh discuss daily huddles, which are a great add-on if you watched our last video about scoreboards.

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Please let us know if there are any topics you would like us to cover in the future.

Lean Assessments

Tuesday, June 1st, 2010

Assessments can be an important tool in your lean journey. Like a compass, they help to keep you pointed in the right direction. In this video, Andy and Jamie discuss assessments versus audits, different forms of assessments, and the purpose of assessments. How have you used assessments in your organization?

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Process mapping in a business environment

Tuesday, April 27th, 2010

In this edition, Andy and Jamie take on the topic of process mapping. A tool that spans beyond lean into every form of continuous improvement, it is often underutilized and misapplied. We focus on mapping business processes, and why both product / process maps and activity maps are so important.

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If you cannot view streaming video, you can go directly to Viddler to download the video. If you are interested in learning more about process mapping, you could attend our Kaizen Boot Camp course or purchase our Single Point Lessons.

Lean in a Union Environment

Tuesday, March 23rd, 2010

In this video, Andy Carlino and Jamie Flinchbaugh discuss lean in a union environment. This is not about pro-union or anti-union, but a recognition that having a union does affect how you deal with change. When it comes to lean transformation, it presents some challenges but also some advantages, because you know the rules and have a clear audience. Check out the video and please share your own thoughts and experiences. We are certain that others would benefit from hearing your perspective.

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