Book Review: Kaizen Event Fieldbook

Mark Hamel’s “Kaizen Event Fieldbook” is an excellent addition to the library of Lean literature.  Don’t let the title fool you though, there is more to this book than just the technical details behind a kaizen event.

The book definitely delivers on the myriad of details for progressing through the different phases of a kaizen event.  Instead of just explaining what to do, the author provides the reason why it is done.  The book’s emphasis on the thinking behind the actions is valuable for Lean leaders, facilitators, and consultants .  While there are a lot of similarities to how my organization conducts events, it is nice to see the differences recommended by the book.

There are many great tables and visuals throughout the book.  A few of my favorites are the decision tree for what should be a kaizen event, a table with nine symptoms of event malpractice, and a team behavioral audit for the facilitator.  There is also an exhaustive appendix with blank forms to use for kaizen events.

In addition to the technical details, the book has a lot of insight for transformational leadership.  I enjoyed the different short stories in the “gemba tales”.  I like to learn how others teach Lean concepts and the book has an excellent chapter where the author does just that.  I am glad the book also discusses the need for daily kaizen and what that looks like in relation to kaizen events.  Lastly, there is an outstanding section about the role of a kaizen promotion office and the core competencies of those who work in it.

The “Kaizen Event Fieldbook” is a book I open often and refer to.  I highly recommend it.

Mark Hamel writes a great blog at http://kaizenfieldbook.com/marksblog/ and can be found on twitter as @markrhamel.

If you liked this post, then try:

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Communication Or Announcements?

Photo Source: On The Sauce http://onthesauce.net/?p=391

You have a new change coming, do you communicate or just announce it?

I define communication as two-way where input and feedback is requested and announcements as one-way “this is coming or it’s already here” kind of messages.

Announcements are not an effective way to bring your organization along on your Lean journey.  People feel done-to or it appears as though they have no voice.  Announcements give the impression of very top-down leadership even if you had some of the front-line staff involved in creating the change (intent versus impact).

For people to be engaged in the change, ensure you are seeking input and feedback from those affected.  Firstly, before you make a change or set a target condition you should have gone and seen the actual process.  Use this time in gemba to get feedback about the problem.  I have seen flipchart paper put in an area for staff to add input prior to developing counter-measures to trial.  Use staff meetings to ask for thoughts before you start improving.

When developing counter-measures, share ideas with stakeholders or involve them in the trial.  Ask them what works or what further adjustments should be made before it becomes the new standard work.  Their input will make a better counter-measure and help them be invested the change.

After the standard work gets implemented, have leadership and key coaches on the floor soliciting feedback and providing clarifications.  The counter-measure may have some missing pieces that are only discovered after “launch” or people may not understand it enough to follow it.  This communication helps your organization sustain the improvement.

Honestly look at your “communication” strategy.  Is it really just announcements or are you actively asking for feedback to be seriously considered?  Did you bump the communication discussion from every agenda and now stuck in the mode of announcing because a counter-measure is developed and ready to go?

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Don’t Call HR Yet!

“If someone isn’t following standard work then it becomes an individual performance issue.” 

Have you ever heard a leader say something like that? 

It is important to help leaders understand that there are many reasons why standardized work may not be followed and creating a human resource performance improvement plan should not be the first step.

A leader must go and see the actual condition that is causing the employee to not follow standardized work (SW).  Leaders need to ask why SW isn’t followed.  Here are some potential reasons:

• They don’t know about the SW: How was the change communicated?  At a team-meeting where not everyone was present?  Via email buried under other announcements?
• They aren’t trained or capable to do the SW: They may not have the tools or the environment does not allow then to follow it.  The training provided might not have been enough for them.
• All situations not considered when creating the SW: In order to respond to customers, the SW may not be capable to meet their needs.  Do not jump to the conclusion that there isn’t a good reason why an employee did something different.  They are on your team because of their hearts and minds and not just a pair of hands right?
• They already discovered a better way: Help them know how to spread improvements discovered by frontline workers.
• No leadership involvement: If leadership does not show they care the process is being followed on a regular basis and helping solve problems uncovered after implementation, then how can you expect employees to care?
• Outcome not achieved but SW still being required: Standardization is not a Lean goal but a tool to help improve outcomes.  If your hypothesized outcome didn’t come true, why are you still requiring staff to follow the SW?
• You aren’t improving the SW: Over time the SW will unconsciously change if the continuous improvement of it is not designed or part of your culture.  The SW may have had elements missing or wasn’t fully tested.
• Leadership has placed the wrong person in the role: There are some people who willfully do not follow SW.  Leadership must take responsibility for this too since they either tolerated bad behavior because of their productivity or have been so uninvolved to know a person does not fit in their new culture.

As you can see, there are many reasons why people do not follow standard work before you need to punish with HR.

What are some other reasons you have seen why SW isn’t followed?

Photo Source: http://wonderfie.blogspot.com/

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