Spotting Waste

When most people hear the word waste we think of trash or garbage, however, waste can be a lot more than that especially when used in terms of lean. In lean terms waste is defined as any activity that uses resources but doesn’t create value for the customer and in the lean world, we’re all about eliminating waste. There are actually eight different types of waste which can be grouped into three different categories known as muda (just waste), mura (waste due to unevenness or variation), and muri (waste or stress on the system due to overburdening or unreasonableness). The eight different types of waste include:

Motion: This form of waste is whenever there is unnecessary movement of people. Some of the forms this can be seen in are traveling to equipment that is shared with other tasks or looking around for information that could or should be readily available for you. Some common causes of this form of waste are work space layout, ergonomic issues or searching for misplaced items.

Waiting: This form of waste is caused when people are stuck waiting for other people, information, products, or equipment which disrupts the process. This waste can look like idle time, customers waiting in long lines, and stopped equipment. It can be caused by the need for an approval or unbalanced workloads.

Knowledge: This form of waste is when an individual’s knowledge or skills is not being used to its full potential. This can be seen in a large amount of approvals or reviews, or the neglect of ideas. The common causes of this waste are lack of trust in the workforce and lack of communications between departments.

Movement: This form of waste is caused by the unneeded movement of things. This can look like hand carrying equipment and rearranging elements. Some common causes of this waste are too much inventory and a poor layout for the process.

Correction: This form or waste is when incorrect or incomplete information has to be corrected or finished when it should have been right to begin with. This can be seen when there are defects, missing information, or dissatisfied customers. Some common causes of this are poor training or communication, lack of in depth instruction, or no standard.

Over-processing: This form of waste is when more is done than what is necessary to produce a product or service. This can be seen in inspections or reviews, redundancies, or approvals. The common causes of this form of waste are an outdated process or a lack of trust or communication.

Overproduction: This form of waste is when more is done or made than what was needed. This can look like queues of work or and abundance of inventory. Some common causes of this are an environmental push or a lack of focus on the value stream.

Inventory: This waste is the surplus of supplies, information, or equipment. It can be seen as stockpiles of materials, supplies or papers. This form of waste occurs when people make or store items “just-in-case” or when there is an unreliable purchasing process.

No matter what the form of waste is, it is always important to know what it is and how to spot it. Lean is driven on the removal of waste in any form to better a process or project so, if you don’t know how to spot it you won’t be able to fix it. Waste is all around us. Look around you now, what waste do you notice just in the room you are in?


Changing Resistance

Change within the work place is supposed to be vital and natural, as the saying goes “change is the only constant.” So if change is supposed to be a natural part of our jobs and business, and it’s meant to be beneficial, why does resistance come with it?

There are many valid reasons why employees may be resistant to change, and the biggest factor has to do with one’s past experiences and the definition that “change” takes on for them. If changes were implemented without good communication, resulted in added stress or hassle, consisted of a lack of trust in higher management, or resulted in downsizing- then employees may associate change with negativity due to what they experienced.

Overall, change is associated with instability, and we tend to be weary of what has the potential to affect our jobs and what we are used to. In Lean and Continuous Improvement one very important aspect of implementing successful and sustaining change is the support and understanding of those involved. Lean and Continuous Improvement integrates respect for people, communication, and purpose into its process of change in order to help the transition from “comfortable” to “unknown.”

 

Respect for people is one of the pillars of Lean, and respecting the people you work with includes listening and respecting concerns they may have with changes to a process. Understanding these concerns allows you to support them, validate them and let them know the ways that change is going to impact, them in a good way.

Communication is always key, especially for when experimenting with improvements. Communication allows for everyone to be on the same page about how the change is being implemented, as well as what their own role will be in the changed process. This establishes control for one’s own role and helps to mitigate any worry about what change means for their position, keeping one empowered.

Purpose is what drives continuous improvement as we try to give a result with utmost value. Establishing the purpose behind a change and “Why” it is valuable to those involved, helps to drive the wheels of improvement. Believing, understanding and being unified behind a purpose allows everyone to understand and conduct change in a way that supports one’s purpose as well as an organizations.

The likelihood that every person you work with will be comfortable when confronted with change and new implementations are not very high seeing as there may always be a degree of resistance. However, when implementing change in a Lean and Continuous way, you try to find the reasons for resistance within your group and then address those concerns. Maybe then, the next time change comes about, you’ll be met with a little more excitement and less resistance.

 

 

 

 

 


What does PDCA look like for you?

The Deming cycle (Plan, Do, Check and Act or PDCA) is essential for monitoring the effectiveness of a process, the standards for a process and the sustainment. This is called a cycle because even after you implement improvements (Plan and Do) within a particular process, eventually you have to look at the process again (check) to see what’s the next steps to improve the process further (Act). This continues on until you reach your target condition, which may change. It’s a deliberate way to reflect on where you’re at versus where you’d like to be as well as recognizing what’s getting in the way.

Recently I’ve been going through some training on how to be a coach for others in a way that is meaningful and true to myself. This requires a lot of reflection on my behalf so that I can understand:

What does being a meaningful coach mean to me?

What does that look like?

What direction am I trying to go?

Throughout my time reflecting in the last two months, I have been seeking these answers and focusing on identifying my current leadership state and my ideal leadership state. Sometimes it’s been a confidence boost, showing me that I’m a hard worker and reliable, sometimes it’s been a little convicting and has made me step back a little in, “whoa, we need to fix that.” At times, digesting my reflections has been a big pill to swallow. However, through my knowledge of PDCA I’ve come to recognize that just like a deficient process, my weaknesses don’t have to define my leadership capabilities (my process), and they don’t have to stay weaknesses.

The PDCA cycle recognizes that you can’t get from point A to point Z in one large step, but rather through: incremental steps (point A to B to C… Z), experiments, and reflections to see if the experiments worked or didn’t. If they did, go work on an experiment for the next step. If they didn’t, try a different experiment. The PDCA cycle was designed to move through the deficits, but it wasn’t designed to ignore the strengths. PDCA uses the strengths of a process to explore innovative experiments that are customized to the parameters of the process. This is how I’ve been using PDCA to help me check to see where I currently am as a leader, as well as to design experiments through the nature of my strengths to transform my weaker areas as a leader and ensuring the cycles are meaningful to me individually.

 

 

Long story short, the PDCA cycle can be used anywhere, even for yourself personally and not just for a process at work. It’s a tool used for reflection, eliminating blame, and accepting that humans aren’t perfect but that we can still strive for something greater by holding ourselves to a higher standard that is meaningful and deliberate.

 


Making Your Phone Productive Again

Smartphones, we have come a long way since the early days of the smartphone. The first ones had trackballs and physical keyboards, some of which slid out from under the screen. Back then they were all about productivity. Finally you could have your cell phone, calendar, email, and a basic internet browser all on one device instead of your Star Trek inspired flip phone and a palm pilot. They were the Perfect productivity tools. Then, in 2008, everything changed with the introduction of the iPhone. Since then smartphones have evolved into slabs of glass and metal used by nearly everyone mainly for games and social media. We as a society have lost the meaning of having a smartphone. Today many phones are many times more powerful than the computer that brought people to the moon and we use it to crush digital candy.

                                                   

250MB Hard drive form 1970’s                                                                           256GB Micro SD Card 2018

Thankfully, there are companies that are looking to put productivity back into the smartphone. These companies are doing this by releasing apps that will track how much time you spend on your phone or help you complete tasks. Among these productivity apps many of them are implementing forms of Lean thinking such as the Trello app that acts as a Personal Kanban. Many of these apps are free and you should definitely check them out. Another useful feature about many of these apps is that a lot of them sync up with your google calendar and have their own website you can bookmark on your computer.
Apps that help boost your productivity can also include those that reduce the time that may be wasted on your phone so you can focus on getting tasks done and not being distracted. One of these is called Forest, it costs a few dollars but what it does can be worth it. Forest simulates a small plot of land on your screen and your goal is to grow a forest, the catch is your forest only grows when the app is open. So, in order to grow your forest you have to open the app and leave your phone alone without opening anything else. The best part is, based on how large your forest is, the company behind the app will plant a certain number of real trees. You could also simply turn your phone off and put it away.
These kinds of apps can be very useful for those trying to live a Lean focused life in the age of pocket capable computers and time wasting crazes. These machines that were made to make our lives more productive have turned into social media and gaming devices that fit into our pockets. So, if you are looking to be more productive and use these wonderful inventions for what they were intended for, look into productivity apps, many of them have aspects of Lean and continuous improvement mixed in.


Personal Kanban

People often find themselves getting caught up in a pile of tasks they need to complete. These tasks exist in their personal lives, work projects, or school assignments. When people get wrapped up in the amount of tasks they are faced with, they tend to not know where to begin. They become uncertain on how to organize and prioritize these tasks. This can lead to missing events or deadlines and feeling very overwhelmed. However, lean tools can be the perfect fix to this overwhelming feeling; one in particular is the Personal Kanban.

A Personal Kanban is a tool used to help visualize, prioritize, and complete tasks. It also aids in managing work by volume and highest value so an individual can see what order tasks should be completed in. This lean tool also works with the individual to help them be successful because it’s directly tailored to the needs of that person. Some main benefits of using this tool are it organizes allotted time, provides a foundation for improvement efforts in work flow, and supports communication and coordination with a supervisor.  There are many different ways to set up a Personal Kanban. This and the fact that it can be used anywhere and it tracks items that are of personal value to the individual. These are what make it personal.

Around the Office of Continuous Improvement many Personal Kanbans can be seen, since all of the employees here use them. They all include tasks and projects we need to complete around the office and when we need to complete them; however, no two look exactly alike. Some of us choose to use an online format, while others go with a simple white board and sticky notes, and others have detailed layouts, but in every case these Kanbans help us all organize our tasks in a way that will help us complete them efficiently and effectively. Also our Personal Kanbans are constantly changing because we are continually trying to figure out the best layout and platform that works for us as individuals. One way to measure how well a Personal Kanban set-up fits you, is to examine if you are actually using it. Because after all, if you’re not using the tool, obviously something is not working right.  If you’re feeling overwhelmed by tasks, expectations, and commitments use the examples below to form your own Personal Kanban and get those tasks organized!

 

PIC Sophie's Personal Kanban
PIC Sophie’s Personal Kanban

 

Office Assistant Alexandra's Personal Kanban
Office Assistant Alexandra’s Personal Kanban

 

PIC Dominique's Personal Kanban
PIC Dominique’s Personal Kanban

Welcome, Rick!

Welcome Rick Berkey: Faculty Fellow in the Office of Continuous Improvement

 

This year, Rick Berkey joins us on a special assignment through Michigan Tech’s Faculty Fellows Program. In this role, Rick will be focusing his efforts on broadening and strengthening continuous improvement in the academic units.

 

Good morning everyone! I’ve been fortunate to get to know many of you across campus in my role as Professor of Practice and Director of the Enterprise Program in the Pavlis Honors College. Some of you also know me through my involvement as a Lean Implementation Leader, where I have facilitated several Kaizen events going back to 2010 when Michigan Tech began investing in a more formal Lean and Continuous Improvement (CI) initiative. I have been at Michigan Tech since 2006, when I transitioned to academia following a successful industry career that spanned 12 years, three companies, and numerous roles in engineering, product development, program management, operations, quality, and continuous improvement.

Five years into my career, I was selected to participate in Honeywell’s Six Sigma Black Belt program, an intense 160-hour training program involving the use of CI methods and tools to improve business performance and success. My certification project was the development and launch of a new product line (still in production today – the FRAM Xtended Guard oil filter). Looking back, my Black Belt experience was career and life-changing for me — the tools and methods “clicked” and just made good sense, and more importantly the corporate culture embraced continuous improvement as a key enabler for achieving its strategic goals and objectives. This experience opened up many doors for me professionally, and in fact my corporate Six Sigma training and Green Belt mentoring activities played a large role in my decision to pursue a career in higher education. Like many of my peers, I find great reward and satisfaction in my interactions with Michigan Tech students — whether it be in my two Six Sigma courses, helping to ignite that same “spark” I felt in my early career; in my advising role to the Supermileage Systems Enterprise; or in the periodic interactions I have with the hundreds of students enrolled in our signature Enterprise Program. Our students are our future, and from what I can see it’s look pretty bright!

 

This year, I “raised my hand” to get more involved in Michigan Tech’s continuous improvement efforts through a part-time faculty fellow appointment. One of the goals I have is to lead by example to show how it can be applied more strategically and successfully in our core academic value streams: teaching, research, and service. Admittedly the language of continuous improvement can be confusing, the tools can be misapplied, and skeptics can and do question its relevance to their work. However, I think CI is quite simple and it really boils down to some key elements that should resonate with employees in any organization:

  1. Continuous improvement is a culture…it’s a mindset that strives for perfection and recognizes that you’re never fully there. It rewards calculated risks and embraces change.
  2. Quality starts and ends with the customer…it’s about knowing your customers, and striving to deliver the quality and value they (and their customers) expect from your products, processes, and/or services. After all, there is always competition and choice in the marketplace.
  3. Customer value is created through processes or value streams…these can be transactional/service as well as manufacturing/product-oriented. Organizations define the processes they use to create and deliver value, meaning they also have the ability to change these processes in order to improve performance.
  4. Waste is anything that doesn’t directly create value for the customer…most processes have significant amounts of waste, and learning to identify and minimize waste in its many forms is a core strategy of a successful CI program.
  5. Continuous improvement is really about building and freeing organizational capacity, not cutting costs and people. Capacity gives organizations agility and options, whether it be investing in new growth, reallocating existing resources to higher value activities, and/or sustaining competitiveness during downturns and market contractions.
  6. Respect for people is the foundation of any successful CI initiative…fundamentally this means empowering employees, harnessing their knowledge, actively involving them in improvements, and avoiding blame (focus on the process, not the person). It also means developing empathy for your customers and their experiences with your products, processes, and services. Finally, it’s also about celebrating the successes achieved together through continuous improvement.

 

I have experienced first-hand how continuous improvement can fuel the growth and success of an organization, enabling it to not only adapt, evolve, and stay relevant, but also to lead in dynamic market conditions. This is what motivates me to take on my faculty fellows assignment this year. The timing couldn’t be better — as we embark on the University’s Tech Forward initiative, I firmly believe our continuous improvement culture and tool-set can and will help us achieve the goals we’ve outlined for our institution’s future. Fortunately we have a good start already, and I’m excited to play a more active role and look forward to working with more of my colleagues. I will be reaching out to many of you soon as I begin working on the initial opportunities we’ve identified. Likewise, I welcome your input and thoughts on areas where you see CI being used to improve the success of our great University.  –Rick


Welcome Sophie!

Joining our PIC team this year is our newest addition Sophie Pawloski. Sophie is a third year, Mechanical engineering student here at Tech. She is very excited to learn more about the lean culture and implement lean into her own life while helping promote it around campus. Now Sophie will tell you a little bit about herself!

 

Hello!

My name is Sophie Pawloski. I was born and raised in a small town in downstate Michigan called Durand. This is my third year here at Tech working towards my Mechanical Engineering degree and it been some of the best years to date! You can probably find me at most Tech sporting events cheering them on with the dance team. In my free-time I also enjoy snowboarding, hiking, and just exploring the Keweenaw.

I was introduced to lean the summer after my freshman year at my first internship working at Magna. They were very involved in lean manufacturing and focused heavily on it at their facility. During my few months there I was able to participate in Kaizens, 5S during change over, and implement many lean ideas, which they called lean thinkers, into the assembly processes there. After this I was able to see the impact lean had on not only the company as a whole, but individual workers as well. In lean everyone’s opinion is valued which can really boost the morale of a company! After this experience lean had me hooked.

Since I’ve started the training process in the Office of Continuous Improvement I’ve learned so many new lean tool that I’m beginning to implement into my everyday life, like how I organize my planner or putting up a whiteboard in my room. I’m so excited to continue this journey and see not only how lean affects Michigan Tech but also how I can implement it into my own life!

 

Thank you!

 

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Lean Hospitals

If you listen to the news, you aren’t going to hear much on car crashes unless there has been a very bad one, or it is just a slow news day and they have nothing else to report. Plane crashes will be on the news whether it was a relatively minor incident, or a major one. This shows the two ways we can view a defect or a problem, either as a car crash, an inevitable incident that is bound to happen, or as a plane crash, a zero tolerance policy.

I recently watched a video that showed how these two different lines of thinking can have an enormous impact on someone’s life. This video was called “Do No Harm” by VOX on YouTube, and it outlines how treating an infection as a “car crash” or a “plane crash” can determine the life and death of patients in hospitals. During the video, an interview is conducted with the mother of a little girl named Nora, who had been born with an underdeveloped lung. Because of this defect, Nora had to have what is called a central line implant: a tube that is inserted into a vein that leads directly to the heart and is used for the speedy delivery of medicine and easy blood draws. An infection of this line can be very serious and extremely life-threatening.  Nora had four of these infections.  Because of these infections, she passed away just before her fourth birthday. Nora’s mother wrote a letter to the hospital where she was treated, outlining what she had seen and offered feedback. The hospital responded with a letter that stated “… We understand and recognize your feelings regarding Nora’s care and we apologize that you were dissatisfied with your experience…” This hospital treated central line infections like car crashes, an unavoidable risk, instead of something that could be prevented.

Central Line

The second hospital shown in the video had a team of nurses who experienced many central line infections a few years back, and they decided to do something about it. They asked themselves if having zero infections was even possible, but one of the RNs at the hospital leading the project stated “You cannot accept good enough, you have to eliminate those [infections]…” The team used two books to aid them in their mission:  “The Toyota Way” by Jeffery Liker and “Toyota Kata” by Mike Rother. With them, the hospital was able to adopt some aspects of Lean and Continuous Improvement, and together, the nurses developed practices that minimize the chance of exposure to something that can infect the central line. The team implemented a zero tolerance policy towards central line infections and this hospital went seven years without a single infection.

Lean books

The video ends with the team going to talk to an expert on central lines and how to prevent infections in them. The expert stated that their first step in preventing infections was treating every infection as a defect, finding the root cause of the problem, and finding a way to prevent it from happening again.

Treating problems in this way is Lean Thinking, and this is a real-life example that shows the way we approach problems can have a real impact on the outcomes. Before, manufacturing had been the go-to example for implementing Lean, but this video is an amazing example of how Lean and Continuous Improvement can be implemented in all kinds of areas, and what the results can look like when it is.

 

 

 


Welcome, Alexandra!

We are pleased to welcome Alexandra Holmstrom to the team in the Office of Continuous Improvement. 

Hello,

I am Alexandra Holmstrom, the new Office Assistant in the Office of Continuous Improvement. I am very excited to be working at Michigan Tech and especially with all the highly dedicated and talented members of the OCI team!

I am new to Lean but as I learn more, I am realizing that I have been practicing many of the principles all along! I have always looked for ways to be more efficient and effective, thinking of ways to improve customer service, reduce costs, and remove unnecessary steps in day-to-day tasks.

There is much to learn and accomplish during my training, and I am eager to use all the newly acquired knowledge and skills. In the few short days I have been in the office, I have learned what Kaizen, PIC, PDCA, and Kanban stand for. If you are wondering what these words and acronyms mean, come see us in the office or visit us on our website.

I look forward to meeting and working with everyone on and off campus!

Thank you!


Welcome Mitchell Carpenter

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Welcome Mitchell Carpenter

A newcomer to our team of PICs is Mitchell Carpenter. He is from Grand Rapids, Michigan, and is currently a Second year Materials Science and Engineering major here at Michigan Tech. He is returning after having finished his training at the end of last semester, but has already started to integrate parts of Lean culture into his everyday life.

Mitchell will now tell us a bit about himself!

Hello everyone, I’m Mitchell and I am from Ada, Michigan, which is just East of Grand Rapids. I went to Forest Hills Central High school and graduated there with the class of 2017. I have been in contact with the Continuous improvement team here at Michigan Tech since the summer of 2017  when I met them at a Lean conference in Traverse City. I was there with the director of Continuous Improvement at a company I had an internship with called Nucraft Furniture. This is where I was first introduced to the concept of Lean and Continuous Improvement.

The philosophy behind Lean and Continuous Improvement has fascinated me ever since I was introduced to it. The fact that there was actually a name for a culture around striving to make things more efficient blew my mind since I have enjoyed problem solving and efficiency since childhood.

I am excited to be a part of the PIC team here at Michigan Tech. I was a part of this office for about three weeks before the end of last year and I can already tell that I am going to like it here. I am thankful for this opportunity and I look forward to learning more about Lean as I continue my career here in the office of Continuous Improvement.