14 Mayıs 2015 Perşembe

amazon highlights: Sunrise Meetings / Giles Johnston / 2013



 

Introduction: What is a Sunrise Meeting?

Firstly, a business that runs like clockwork experiences fewer surprises. Tasks run to a schedule and you can set your watch by them. These routines keep the entire business working in the way it was intended.

It is my experience that disciplined routines can make a huge impact on the way a business performs. Routines need to be implemented from the position of properly understanding how your business processes are meant to work and this is the first port of call in this book.

I have seen businesses that operate in ‘organized chaos’ move to progressively improving levels of performance via Sunrise Meetings. A Sunrise Meeting is a great way to capture the effective routines in your business and keep them in place.

A business that is working the way it was intended has a firm grip on the standards it needs to work to. These aren’t just external accreditations but the ways of working that keep the business going.

Sunrise Meeting approach can help you to increase the performance of your business.

The Sunrise Meeting approach is one way to bring together the necessary routines, standards and Key Performance Indicators (KPIs) that can help you to run your business effectively.

 

Benefits Of A Disciplined Approach To Working

First of all there is the peace of mind that comes with routine and discipline.

When routines are defined properly then your teams can work more harmoniously.

Routines can help you to become more productive.

 

Sunrise Meeting Examples

The main issue that this business faced was the lack of clarity about what needed to be done when.

Through tiny meetings and small bursts of activity the admin backlog disappeared (in only ten minutes a day of concentrated effort for two weeks) and consequently their cash flow improved.

At the shift crossover, at midday, was when this business held their Sunrise Meeting.

This business opted for a fortnightly review meeting as it better reflected their project lead times.

 

Principles To Consider

Disciplines can decay

ensure that your tasks are reviewed regularly and disciplines can be restored quickly if they do slip.

People forget what's important

Having a reminder to help people do the right things can make a big difference.

Complexity kills efficiency and effectiveness

Little and often beats big and infrequent

After all it is easier to relax the frequency of a meeting schedule than to tighten it up. Our routines can often benefit from smaller tasks being looked at more frequently.

 

PART ONE – Sunrise Meeting

Step 1: Map Your Process

it is a good idea to construct a quick process map of how your business works to quickly define what the key tasks are. It should be that each step in the process can be defined by a single word, or short sentence. It is the essence of the step that I want you to capture. You will capture the key tasks as part of this step in the exercise. The tasks must directly support the process, not be tasks that keep people busy!

- Create a simple process map, like the one on the next page, for a business process of your choice. Keep the steps at a high level.

- When all of the steps have been listed add in the handful of main tasks that need to happen in order for the process step to ‘complete’.

- Any issues that are generated as the map is completed should be noted for your continuous improvement activities (or possibly your issues board).

you recall the ‘jar of rocks’ time management story you will relate to this.

creating your top level process map you are attempting to (re-)identify the ‘big rocks’, which can then be used to increase your effectiveness.

 

2: What's Not Happening?

next step is to build upon the top level map you created in step 1 and add in the other ‘irritations’ that affect day to day business performance. I want you to capture in this step of the exercise is a list of tasks that aren’t happening. You know that the core tasks listed on your top level map need to happen and now you need to include the other items that don’t happen as well.  clarity over which tasks aren't happening is essential so that you can correct the situation.

- Create a table with three headings; task, frequency, notes.

- List the tasks that aren’t happening, their appropriate frequency and any additional notes.

- Try to be as exhaustive as possible, considering supporting areas of the business that affect the business process you have chosen to review.

there may be tasks spread out over days, weeks and months. Try to capture all of your tasks across these different timescales.

 

Step 3: Shortlist Of Tasks To Be Regimented

After completing the previous step of this exercise you may have a really large list of tasks that don't happen, but should. By prioritizing the actions you will take there will be less to do immediately and therefore make the transition easier. If you are struggling to choose which items are going to be selected ask yourself if the task is linked to any others in the list. By rationalizing your list you give yourself the opportunity of an easier change with the potential for expansion if appropriate.

- Review your list of tasks that don’t happen and prioritize their importance.

- Eliminate tasks from your list if they are symptomatic of other items in the list that aren’t happening currently.

- Select the tasks you want to include in your daily Sunrise Meetings.

 

Step 4: What Needs To Happen Each Day?

You should have a combined list of key tasks from your business process to consider and a number of prioritised tasks that are not happening the way that they should. It is a good opportunity to capture these items in one place, which is the purpose of this step. By duplicating the format below (including yearly items) you can quickly create your time table. This fundamentally is the routine for your business, and from which we can create the Sunrise Meeting and other supporting meetings.

- Convert your lists of key process tasks and other outstanding tasks into a timetable using the above format (or create your own).

- Re-review the time scales to see if you have missed any tasks from the first attempt.

 

Step 5: Designing Your Sunrise Meeting

The purpose of the Sunrise Meeting is to get your team together near to the start of the working day. At this meeting a short series of questions are asked and any corrective actions are planned. The meeting should be aligned with the performance objectives you are working toward and should only last a few minutes. Any issues that get raised during the meeting need to be captured, monitored and closed out at the subsequent meetings.

Your job is to convert the daily routines and key process activities into a logical sequence of checks that can form the agenda for your Sunrise Meeting. Getting the right people together to discuss these points also needs to be considered. You may wish to include additional people who do not directly report to you, but who can answer the above questions.

- Review your daily routines and the key process activities and create a series of simple questions.

- Review the questions and see if you can adjust the questions so that you can elicit a ‘yes’ or ‘no’ answer.

- Determine who the right people are to take part in this short meeting, including people who are possibly not direct reports.

- Choose a meeting area that is open and preferably one that contains a whiteboard to capture any issues that arise from the meeting itself.

 

PART TWO – Improving Your Sunrise Meeting Results

The First Sunrise Meeting

When you hold your first Sunrise Meeting it will most likely take too long. Accepting that the meeting will evolve in terms of both its duration and its effectiveness is all I ask for the short term. It is clear that the better prepared people are when attending meetings the quicker the meeting can be. This goes for the Sunrise Meeting as well as other meetings. Being clear with everyone about the duration of the meeting is vital to keeping the sessions short. Long meetings are often far less productive than short, well planned, meetings. To ensure that everyone understands the importance of a Sunrise Meeting it is imperative that the meeting takes place consistently. Every day the meeting must be run and the agenda followed. It needs to become a habit and so if you are the person who is going to run the meeting then you need to plan in advance who will run it in your absence (holidays etc...).

Starting on time is another strategy that I urge you to use. The Sunrise Meeting is focused on bringing a more systematic and organized approach to running the operational side of your business.

Waiting for people to turn up is frankly unacceptable. If people are going to turn up late then they should be reminded firmly that lateness is not the standard you are striving for.

Finally, make the meetings count. Most people who have been told they have to go to a new regular meeting will be sceptical of it producing results. Sunrise Meetings can be as much about the style of delivery as the content.

- Review the planned participants for the Sunrise meeting and decide on what style you need to have in order to run an effective meeting.

- Make it clear to all that the meetings happen every day at the same time and that they start on time.

- Monitor the response in the business to this way of regulating operational activities, possibly via your KPIs.  

- Adjust the agenda if you think it necessary, based on your observations from the above point.

 

Can We Go Home Yet?

Quite often the working day can be interrupted with issues. Sunset Meetings can be used in two main ways. The first way, to support the development of habits, is as a short term arrangement. If the Sunrise Meeting is the ‘take off’ then the Sunset Meeting is the landing. Whilst the Sunrise Meeting is scheduled (usually) for the start of the working day, the Sunset Meeting is often scheduled for near to the working day, but not right at the end. Often the mistakes and problems from one shift are left for the other one to deal with!

In my opinion, the Sunset Meeting should have an even shorter agenda and a quicker pace than the Sunrise Meeting. of running through the same agenda it should simply check of the actions that were agreed at the Sunrise Meeting. Going back to the timing of the Sunset Meeting, if there are still actions outstanding then there should be enough time left for the people who need to take action to do so. I’ll leave you to make up your mind as to whether you think there is merit in running a Sunset Meeting in your business, either to form habits or to close out the working day / shift.

- Review your Sunrise Meeting agenda and create a cut down version.

- Choose a time in the working day to run your Sunset Meeting, where your team will have enough time to undertake the outstanding actions.

- Ask yourself the question ‘does this agenda support team working and getting the business on track?’

- Hold your first Sunset Meeting, explaining the purpose you are introducing it for, and test your agenda.

- Monitor the rate of closeout of actions and adjust your Sunset Meeting agenda as appropriate.

 

Other Routine Meetings

There are various levels of review in any business and the Sunrise Meeting is definitely at the operational level.

Having these different levels of meeting at your disposal will help you have even greater control over your business. In summary, these levels are:

- Operational: Did we pull the levers today?

- Tactical: Have we selected the right levers to use?

- Strategic: What are the right levers we need to create?

 

‘Projects Review’. - ‘Contract Review’. - Management reviews - ‘process improvement’ meeting

 

- List out the management meetings that you have in your business currently.

- Identify the missing items (things that don’t get done, but should) and list them against the appropriate meeting.

- Find the standard agenda for each meeting (if there isn’t one write one).

- Add the missing items to the agenda at the appropriate place.

- Step back from each meeting and clarify the value in having the meeting in the first place. If the value is poor ask yourself if you could replace the meeting with some other approach (e.g. an email that is circulated through a specific path of recipients, adding comments each step of the way, or splitting the meeting elements into other meetings).

- Ensure each meeting captures actions for subsequent follow up.

- Review the time required for each meeting and attempt to reduce it.

- Ensure that each meeting starts on time and finishes on time.

- Keep side issues out of the meeting; let the right people deal with them in the right way.

Meetings only add value to a business when decisions are made; please bear that in mind when reviewing yours.

 

- Review your routines and split your non Sunrise Meeting items up into logical groups. Add these items to the relevant existing meeting agendas.

- Consider a weekly capacity review / MPS approach to help regulate the levels of resource you require.

If you have complex projects, or are juggling varying capacity levels, then consider the use of a contract review meeting to help smooth out capacity and load your business appropriately.

- Use the tips above to trim your existing meetings.

- Consider a specific process improvement meeting to help move the business forward and reduce the overall level of fire fighting that you have to do in your business.

- Ensure that your rota of meetings add value to the business.

 

Piggybacking Existing Meetings

put a short written statement at the top of the standard meeting agenda of what the purpose of the meeting is. The first way is to create a micro version of the meeting, including only the absolutely essential elements. As the meeting develops, generating results for the business, then the additional elements can be brought in to the mix. The second way to use the tiny version first method is to take the idea of only having one or two items but instead of having a separate meeting you attach them to another meeting’s agenda. This of course requires that your additional agenda items are short to discuss and don’t bloat the other meeting. purpose of this book is not to take up more of your business time with meetings; it is to help your business to become more effective through a combination of routines and short meetings.

- Add a purpose statement to your standard agendas.

- Establish the ‘micro’ version of your meetings if you are short for time.

- Consider piggy backing your essential meeting points to another (relevant) meeting if you can’t get the right people together for a separate meeting.

- Develop the agenda points over time and see if they require a meeting of their own (if you have tried the piggy backing approach).

 

The Issues Board

The first reason to have an issues board is to stop people having to remember what the issues are in the business. From a ‘servant leadership’ perspective the issues board is an opportunity for you, as a manager, to clear obstacles from your team’s path. When the ownership of a board is not clear it does not get used properly, which in turn can make the board irrelevant to the business and the meeting attendees. When an item is placed on the board it is vital that the board is kept up to date and that progress is visible. Deciding on how long an issue can live for on the board is a good consideration. If the issue that isn’t moving isn’t simple and / or low cost to resolve then it may be worth breaking down the actions required into smaller packets. Rules about what goes onto the board should also be made clear. This point is similar to the need to keep the board clean and tidy so that it is treated in the way that it needs to be.

- Include an ‘issues’ whiteboard in the area where you will hold your Sunrise Meetings.

- Determine who will ‘own’ the board and what the rules are for including items on the issues board.

- If you own the board then find ways to proactively ‘kick down the locked doors’ and support your team via this board.

- Determine if a shelf life for issues is appropriate. If it is then ensure that old items are flushed from your board periodically.

- Consider breaking down more complicated and time consuming issues into smaller pieces to help your team schedule them more effectively into their diaries.

- Use root cause analysis whenever possible to ensure that you are solving the right issue and not just putting sticking plasters on problems.

- Determine an effective board layout to facilitate the resolution of the issues.

 

The 5 Why Approach

Don't try and solve a symptom, solve a root cause.

- Try out the 5 Why approach with your team.

- Get the hang of asking good questions in order to make this approach effective.

- Use it prior to raising issues for the issues board at your Sunrise Meeting.

 

Time Tables And Flexibility

In addition to the tasks that need to be performed you can also add in any reference to Standard Operating Procedures (SOPs) that may be relevant. Doing the fun stuff first and then playing catch up is not the correct sequence! Discipline, not rigidity, is the focus here. The times in the timetable don’t have to be prescribed if they are not relevant.

- Implement timetables for staff that need guidance with managing their own time.

- Link the timetabled action to SOPs if available.

- Use the timetable as a training aid for new members of staff.

- Be flexible with the timetables to get the right balance between internal on time delivery of tasks and allowing individuals to work independently.

 

Use Meetings To Reboot Your Team

This is just like a business; we all need to find ways to re-boot our teams so that they work as effectively as possible.  

 

Is There Anything Missing?

- Put a reminder in your diary to review your meetings rota after 1 month, 3 months and 6 months.

- Challenge the meetings; are they adding value to the business?

- Are the right people attending the meetings?

- Are the right topics being reviewed?

At each review look for opportunities to improve the meetings themselves.

 

Short And Sweet - 'Doing The Tasks In Record Time' Challenge

Competition is greatest when it is against ourselves, and how we deliver our products and services is a great thing to improve, so let's take the opportunity. Be tough on your routines. Can you do them faster and better? Work with your team to periodically review the routine elements of your business and find improved methods and processes that you can test.

- Change processes in a controlled manner. Agree the changes first and don’t just change methods without testing them, agreeing them and updating your instructions / SOPs.

 

Policing – Routines Are Not A Magic Bullet!

Choose who will take ownership of which parts of the business. Use this opportunity to link certain senior members of the business with various key parts of the business (if they aren’t already). Don't do the checking from the comfort of your office though - go to the right place and see it in action. Agree on which senior managers should be linked to what processes (from an ‘auditing’ perspective).

- Don’t just rely on KPI data, get out there and go and see what is happening.

- Arm yourself with a handful of questions, if it is you doing the review, so that you can find out if the causes in place are giving you the right effects.

- Use the other routine meetings to make sure that any changes required are implemented.

 

Final Thoughts

The main knock on effect of establishing disciplines is that small disciplines grow over time and standards of working improve.

 

10 Mayıs 2015 Pazar

Yeni Paradigma 2014 / Optimist İdea hakkında düşünceler

Optimist Yayınlarının bir derlemesidir. Paradigmadaki değişim ve Kısıtlar Yönetimi bakış açısıyla değerlendirdim ve örtüşen noktaları listeledim. Ana fikirler:

  • Doğrusal dünya bitti
  • Değişkenlik ve kırılganlık ciddi boyutta
  • Optimizasyon ve tahmin yerine öğrenen organizasyon ihtiyacı var
  • Dengeli ve sürdürülebilir büyüme sağlanmalı
  • Kısıtlı olan para-zaman-insan kaynakları toplumun ve şirketlerin en öncelikli ve amaçlarına en uygun alanlarına yoğunlaştırılmalı


Paradigma Değişiminin Tarihsel Çerçevesi / Zülfü Dicleli
  • Gerçeklik değişince paradigma da değişir, yoksa onu algılayamaz, dolayısıyla tepki veremez hale geliriz.
  • Eski paradigma makine kesinliğinde bir işleyişti, yeni paradigma öğrenen bir canlıdır.
  • Veri yığını içinde gerçekten işe yarayanı seçmek her zamankinden daha önemlidir.
  • Çeşitlilik, değişkenlik yeni dönemin karakteristiğidir.
  • Sürdürülebilirlik anahtardır.

Kalkınmada Yeni Paradigma. Bütünsel Kalkınma Yaklaşımı / Can Fuat Gürlesel
  • Kapitalizm ve piyasa ekonomisi "ekonomide kaynakların etkin dağılımı" sorununu çözmekte yetersiz kalmaktadır.
  • Bütünsel kalkınmanın temel unsurları dinamiktir, sürekli iyileştirmeyi gerektirir, dolayısıyla optimize edilemez.
    • Ekonomik gelişmişlik : istikrarlı büyüme, yenilikçilik ve ticarileşen yenilikçi yaklaşım
    • Sosyal gelişmişlik : 
    • İnsani gelişmişlik : giderek artan sebep-sonuç ilişkisi, sorgulama becerisi ihtiyacı var
    • Sürdürülebilirlik : verimlilik artışından kaynaklanmalı ve doğaya karşı sorumlu olmalı 
    • Yönetişim : bu unsurda yerel optima riski var..

Sürdürülebilirlik İçin Her Alanda İnovasyon / Ayşe Bilge Dicleli
  • Sanayi toplumunun dayandığı doğrusal dünya bitti.
  • Büyümek için kaynaklar sınırsız değildir, etkin kullanılmalıdır.
  • Doğrusal dünya sürdürülebilirliği kirlilik yaratarak zorlaştırır.
  • Sorunların çözümü kazan-kazan olmalıdır, ödün vererek gelişme sağlanamaz.

Ekonomi Nereden Kırıldı? / Orhan Erdem
  • Doğrusal dünyanın ekonomi kuramı rasyonaliteye dayanır.
  • İnsan ne ölçüde rasyoneldir? Veri yığınından karar için gerekenleri ne ölçüde süzebiliyoruz?
  • Doğrusal dünya "tümden gelim ve tüme varım" ile parçaların toplamının bütünü temsil edeceğine inanır. Gerçekleşen maalesef bu değildir. 
  • Doğrusal dünya bu sebeple "tahmin edilebilirliğe" inanır, ancak yeni dünyada belirsizlik ciddi boyuttadır.

Karmaşıklaşan ve Kırılganlaşan Bir Dünyada Yönetim / Işık Deliorman Aydın
  • İkilemler dünyasındayız. "Ya o, ya bu" çözümü işe yaramıyor, "hem o, hem bu" çözümü gerekiyor
  • Veri yığınından işe yarayacak veriyi süzebilmek önemli.
  • Verimlilik tanımı önemli, amaca uygunluk ölçülebilmeli.
  • Değişimi kimse kucaklamıyor. Sebep-sonuç ilişkisi kurulamıyor. İçinde bulunulan gerçeklik ve alışkanlıklar görmeyi zorlaştırıyor. Değişime liderlik edilmesi gerekiyor. Değişim iyi sonuç aldırmalı ve sürdürülebilmeli.

Pazarlamada Yeni Paradigma / Temel Aksoy
  • Tarım toplumunda kıt faktör topraktı, dünya doğrusaldı, azalan verimler kanunu geçerliydi.
  • Sanayi toplumunda kıt faktör sermayeydi, dünya doğrusaldı, azalan verimler kanunu geçerliydi. Kontrol ve hiyerarşik örgüt vardı. Ürünü piyasaya itmek yeterliydi, talep arzdan fazlaydı.
  • Bilgi toplumunda kıt faktör bilgiydi, doğrusal değildi, azalan verimler kanununa uymuyordu. Paradigma öyle hızlı değişti ki fark bile edilemedi.
  • Bolluk fiyat baskısı yarattı, talep arzın gerisine düştü, rekabet arttı, üreticinin sorumluluğu ürünün hayat döngüsünün tamamına yayıldı, kişiselleştirme başladı, tüketimden deneyime evrildi
  • Geri bildirim, gönüllülük, şeffaflık, hesap verebilirlik, sürdürülebilirlik gibi kriterler önem kazandı.

6 Mayıs 2015 Çarşamba

amazon highlights: On Time Delivery / Giles Johnston



Part One - Before  

Manufacturing Engineer

My combined role of manufacturing projects and ERP insights was played upon by my manager at the time and this led to me unintentionally giving the Production Control team a hard time. What was intended as an opportunity for improving the flow of product through the business ended up being a tool to highlight flaws in the existing management approach.

 

5S – My First Dabble With Lean

- Take an improvement approach, realize the underlying principle and then make that fit your organization.

- Be a role model when undertaking change.

 

Process Flow Analysis

The combination of tools; Process Flow Analysis, Spaghetti Map and Concern – Cause – Countermeasure is a powerful mix to help analyze and re-design your production layouts.

- Challenge everything during the review of a production layout.

- Use facts and not opinion to make decisions.

- Take proper action when making changes; don’t let people have a way out.

- Force problems out into the open if you really want to solve them. If you don’t live with the problem you don’t have to fix it.

Part Two - During  

Back to Old School - Fact versus Fiction

If you deliver 999 of the 1000 items in an order your OTIF is 0%.

If you deliver 1000 items then your OTIF measures 100%.

One order in two delivered fully and your OTIF becomes 50%.

- Find the real information about where you are before you start your journey.

- Make ERP / MRP / MIS report writers your friends (either yourself, or via a reliable colleague).

- Check the integrity of the data before you start to publicize it.

 

Polishing Gems

- Don’t lose sight of the problems you have in your business, capture them for later if you can’t deal with them right now.

- If something doesn’t work, keep it in your sights until you fix it, or you work out how to fix it.

- Most problems can be solved with simple solutions. If your solution isn’t simple (and really effective) keep working on it.

 

Beyond Breaking Point

- If something isn’t working create a mini project.

- Keep your mini projects visible.

 

More Gem Polishing

- Process improvement can be tough, not to mention lonely, if you don’t have some supporters or team mates to work with.

 

Updates: Coming Clean and Gathering Momentum

- Give your cause a title, a project name, or a pet name. Something that people can refer to, or even better, resonate with.

- Don’t scrimp on the updates. Keep people informed as to what is happening on the change projects. Especially explain how it will affect them (and when if possible).

- Make sure your facts are right before you go public with this kind of information, ensure that these are facts that you have personally reviewed and not based on hearsay.  

 

Capacity Management

The logic was based on the fact that we had split our bespoke manufacturing into generic families years earlier. All I wanted to know was ‘how much of your available capacity does one unit of each family type require?’ I phrased it simpler than this when asking my question: “How many of X could you make in a week if that was all you were working on?” So, simply, if they could make 50 Xs in a week, then each X equates to 2% of the overall capacity (100% / 50 = 2%).

My colleagues and I also ensured that the routings were up to scratch and that the Bills of Materials were also up to scratch. We wrote some simple system reports that reviewed these records against our standards and corrected the exceptions. We didn’t have time, or the will, to go through the records one by one.

- Ensure that all of your system data is healthy, that it can be relied upon to make decisions from.

- Review your capacity management information and assumptions on a regular basis. Make it into a housekeeping routine if possible.

- If you don’t have a capacity tool of some kind, learn how you identify capacity within your business and create a simple tool to regulate it. The example in this section can work fine for many businesses, although it may only be a starting point for your final requirements.

- Implementing systems is always a journey. After you implement a system, however small, you will usually have new insights and ideas on how to make it better. Whilst in the early days you may want to go back and revise the systems or tools at the point of realizing the need for change. It may be better later on to do this in stages (i.e. queue up all the ideas and do them all at once, every three months).

- Doing something that is nearly right is often much better than doing nothing at all.

 

Balancing the Order Book

The spreadsheet was woefully out of date as you could imagine, so we had an amnesty and the majority (I’m being realistic) were destroyed. From now on we would use the system generated ‘work to lists’ only.

Again there was friction with teams from just doing this. I had instructed them to work to the schedule as prescribed, start at the top and work down. They however were working on the old school approach of finding out what orders were the highest monetary value and concentrating on them first.

- An uneven order book is unworkable in most situations, strive for balance and control over the loading of your work centers via the order book.

- Focus on getting the sequence right and don’t allow people to (solely) focus on the turnover aspect. Working on promises can yield better OTIF results quickly, and after all, the sequence is the job of the Master Scheduler who should have already balanced out capacity and turnover requirements prior to the schedule being launched into production.

- Enforce the necessary disciplines and don’t let the standard drop.

 

ERP on ‘Steroids’

- Work with your teams to understand their information requirements, and where practical, tailor their information / reports accordingly.

- Ensure that enough training and guidance is supplied to your teams to get the right quality of transactions (entries) on your SFDC system, poor entries aren’t worth working with.

- If you are experiencing the hockey stick curve in your business then you may want to review the loading of your order book and / or the flow of products through your business.

 

Contract Review

The next step for me was to simplify the format of the capacity plan and make it available for the Sales team. I wanted them to load the business from now on.

- Work with your colleagues closely when implementing change. Agreeing on a compromise to achieve the end result may well be worthwhile and can improve buy in.

- Don’t confuse reluctance with a lack of understanding. Be willing to spend time with people critical to a process to ensure that they really understand it. In my experience people would rather do a bad job than come clean and tell you that they don’t know how to do something...

- Follow through on your threats, especially when it comes to people mucking about with your production schedules!

- Be clear about where you add value in the organization and try to engineer ways to get yourself out of the low (or negative) value adding activities.  

 

Adhering to the Schedule

- Keep your capacity planning tools up to date with current information. - Aim to get your teams focusing on the smallest unit of time possible that is relevant to the type of production you are involved with.

- Try to avoid delivering on the 37th of each month!

- Change can take time, find the pace of your team when making changes, they won’t necessarily travel at your pace (which is usually faster than theirs) so beware!

 

Continuous Improvement Breakthrough

- Continuous Improvement needs people, get involved with your people and get a conversation going. After a period of time, and a few quick wins, gently steer the conversation and see what the team can do on their own.

- Take advantage of the ‘8th waste’, untapped human potential. I walked past the oven for years prior to the improvement being made. I was unaware, but the team in the area knew all about it but were reluctant to make the suggestion until the time was right.

- Certificates can be fun!

 

Making Myself Redundant

“When I’m finished the Team Leaders will be able to run the production themselves, the tools I am creating means that they will have the ability to do the work that I currently am and they will fill the gap before I leave.”

 

Lead Time Reduction

- If you are progressing with Lean then killing the queues between departments / work centers is critical. Understanding how the work is passed from one function to another is essential if you want to find out how to shrink the lead times. Conversations are the key.

- If you are setting a target to achieve, it is best to share the target and get people to agree to the target. This is something that I should have done in this instance...

 

OTIF Gains

- Share good news whenever possible.

 

Exception Reporting

- When fixing problems, don’t just fix the problem, identify the patterns and underlying issues and fix those. Build them into your systems of working and ensure that you never slip back.

- Where possible try out exception reporting, spend your time and efforts in the right places at the right times.

- Share tools and techniques with your colleagues so that everyone benefits from the improvement opportunity.

 

Winning New Business

Our shorter lead times and more reliable delivery dates was putting us ahead of the competition, during the remaining period of time working for this business we took on an additional 30% of sales based on these three customers.

Now I had a tangible outcome from the work we had been doing. The improved on time delivery was great, the shorter lead times were brilliant, but unless it counts for something then what is the point? In this story the improved performances helped us to win more business, what a great outcome.

 

Automation

Every other tool was a system driven report, so you couldn’t really do anything to break them.  

 

Part Three – After

What Happened Next

The factory is now closed.

No one I know understands all of the reasons behind the rationale used to arrive at this decision, but it reinforces the notion that you can only control what you can control.

 

What Would I Do Now?

So, in this section I will share with you a number of these improvements that I would do if I had to repeat the story.

 

Improved Vision

I would have spent more time at the start of the work to envision how I could see production working, and spent more time working with others to get their input and buy in so that we could all work on one project. I can see how it all happened in retrospect, but at the time it seemed hard to pull all of the pieces together, I was also (seemingly) on my own...

 

Gain Support from Senior Management

I did a lot of work in isolation and without a decent level of support, or sponsorship, during my mini projects.

I took the new job role as a vote of confidence, which it was, but perhaps I should have demanded more interaction and support from my boss. Other senior managers and directors could have been called upon, and, if I had done this, I’m pretty sure I would have avoided a number of the problems that I encountered along the way.

 

Spend More Time on Gaining Buy In Before

I had gone too far into any one part of the improvement projects I would have spent more time gaining the trust and buy in from the people who needed to do the work and who were going to experience the changes. I think I did a fair job with the Team Leaders who reported to me, but outside of this I would have tried harder had I done this again. I’m not suggesting that you go mad with the ‘project stakeholders’, but a little can go a long way.

 

Package the Work

My wall of improvements was all over the place, they were bitty. Pulling three or four of these small projects together could have formed a nice little project in its own right. Some pieces of work could have been made more visible, more symbolic, showing that change was taking place, and that it was a good thing. Being a little more organized about how the work was structured into practical packets of work would have made it easier for other people to get on board. I feel for many that the change just crept up on them.

 

Conclusion: What about You?

I don’t think that a particular technique or method is going to solve all of your problems. I think being open to new ideas and techniques is vital, but making your own choices and creating your own approach to improving your business is key. No one knows your business better than you and only you can craft your own approach ultimately, although books and supporters can help significantly along the way.

amazon review: On Time Delivery / Giles Johnston

On Time Delivery: A Real Lean Manufacturing Story (The Business Productivity Series Book 12)
On Time Delivery: A Real Lean Manufacturing Story (The Business Productivity Series Book 12)
Giles Johnston

2.0 out of 5 stars very basic story, unfortunately no TOC reference was given, May 6, 2015
 I have been involved with TOC for a while. I read the book and recognized Drum, Buffer, Rope, 9 Layers of Resistance, local vs global measures, ... as expected no one of them tagged as Theory of Constraints concept.
I suggest a DBR book like Manufacturing at Warp Speed or Supply Chain at Warp Speed for the interested readers. Then you would have a good understanding of Why to change? What to change? What to change to? How to cause the change? How to sustain? which are all basic TOC questions.