Own Your Lean Journey:

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One of my favorite quotes by Taiichi Ohno came when he was scolding a supervisor for not coming up with his own ideas to solve the problem at hand. The supervisor was trying to do just as he was told. Ohno remarked;

“You are a fool if you do just as I say. You are a greater fool if you don’t do as I say. You should think for yourself and come up with better ideas than mine.”

If we are to heed Ohno’s words, he is asking us to “own” our lean journey and avoid copying Toyota because Toyota’s solutions are specific to Toyota’s problems. If we do not have Toyota’s problems, their solutions might not work. Even Toyota has evolved and adapted to continue being the leader of the automotive world.

In a similar vein Ohno said the following;

“Defend your own castle by yourself!” (Source: Tom Harada)

Ohno wants us to take charge and be in control of our own destiny. These are strong words for a Lean Leader. Ohno’s teachings and sayings are very similar to several of the Zen koans – not everything is straightforward, and they have rich and deep meaning. Ohno’s quotes remind me of a quote from Buddha;

“Don’t blindly believe what I say. Don’t believe me because others convince you of my words. Don’t believe anything you see, read, or hear from others, whether of authority, religious teachers or texts. Don’t rely on logic alone, nor speculation. Don’t infer or be deceived by appearances. Find out for yourself what is true and virtuous.”

Buddha’s words add a deeper understanding to what Ohno said.

Final Words:

The essence of Ohno’s advice is about understanding our problem at hand and going outside our comfort zone. Being inside our comfort zone means that we are not venturing out on our own, we are copying what we have heard or seen. By understanding the problem at hand, we can propose countermeasures, experiment with ideas and break the mental models holding us back.

I will finish this off with a story about Buddha;

Buddha was teaching his disciples one morning.

A man came up to him and asked Buddha. “Does God exist?”

“He does,” Buddha responded.

About noon time, another man came to Buddha and asked, “Does God exist?”

“No, he does not,” Buddha replied.

Later that day, a third man came to Buddha and asked the same question, “Does God exist?”

“That is for you to decide,” was Buddha’s answer.

After the man left, Buddha’s disciples started questioning him. “Master, why did you give  such varying answers to the same question?”

Buddha smiled and replied, “Because they are all different people, and each one of them will reach God by his own path. The first man will believe what I say. The second will do everything he can to prove me wrong. The third will only believe in what he is allowed to choose for himself.”

Always keep on learning…

In case you missed it, my last post was Aim for System Optimization with Kaizen.

Aim for System Optimization with Kaizen:

Local

Kaizen is often translated as “Continuous Improvement” in Japanese and is identified as one of the core themes in lean. In today’s post I am looking at the question – can kaizen ever be bad for an organization?

In order to go deeper on this question, first we have to define kaizen as a focused improvement activity. The question at this point is whether we are optimizing the process. Merriam-Webster defines Optimization as;

Optimization – an act, process, or methodology of making something (as a design, system, or decision) as fully perfect, functional, or effective as possible.

In my opinion, kaizen does not mean to optimize the process to 100% perfection. My point of contention on this is that kaizen should not be about local optimization. Local optimization means to optimize a process so that it is fully optimized without taking the whole system into consideration. This leads to tremendous waste. The local improvement should not cause a problem to an upstream or downstream activity. My best analogy is to work out the upper body without taking the lower body into consideration. This leads to a disproportionately developed body. In a similar vein, Prof. Emiliani views kaizen as a non-zero-sum activity – “everybody wins’!

Let’s look at an example. As part of a kaizen event at a hospital, the intake staff was able to make the client intake process very efficient. They were able to show that their improvement activities resulted in a much shorter time for client intake and they were able to get more clients in through the door. However, this caused more problems at the downstream processes. The staff at these processes were not able to serve the higher number of clients adequately which resulted in higher customer dissatisfaction and staff burn-outs.

Kaizen is a gradual and small incremental change towards the ideal state. The key point here is “ideal state”. How would you define “ideal state”? The “ideal state” means the ideal situation for the organization as a whole. Taiichi Ohno, the creator of Toyota Production System, said that “No standard = no kaizen.” The standard defines the process at its current goal and has three elements;

  1. Takt time – the defined rate of production to meet customer demand
  2. Sequence of work – the defined sequence of work to ensure safety, quality and efficiency
  3. Standard Work in Process – the defined inventory required to ensure that the takt time goal is met

Toyota’s goal is to improve overall efficiency and not local efficiency. This defines the goal of kaizen. Break the current state and create the new standard – while keeping the overall efficiency in mind. Ohno’s favorite way to challenge the current standard is by asking to use fewer operators to achieve the same required output.

Management’s Role:

What is Management’s role in all of this? Management has to lay the framework for everything to function properly. Dr. Deming, the pioneer of continuous improvement activities, says the following;

It is management’s job to direct the efforts of all components toward the aim of the system. The first step is clarification: everyone in the organization must understand the aim of the system, and how to direct his efforts toward it. Everyone must understand the danger and loss to whole organization from a team that seeks to become a selfish, independent, profit center.

Source: The New Economics, Dr. Deming.

Final Words:

It is important to view the improvement activities from a big picture standpoint. Viewing kaizen from a system standpoint is essential. I have always been curious about how the small incremental improvement activities would make a big difference in the end.  I will finish this post talking about the 800 year old Bronze statue of St. Peter holding the keys to Heaven in St. Peter’s Basilica in Rome.

St Peter

It looks like St. Peter is wearing shoes on his right foot and sandals on the left foot. Over eight centuries, pilgrims have been touching his right foot that is more accessible (it sticks out more) and asking for blessings. No one has been rubbing on the foot or sanding it down.  There has been no complaint of vandalism or apparent damage to the statue. The simple act of touching and kissing over time worn the bronze statue down – that St. Peter lost all his toes on his right foot. It is said that the Church started requesting visitors to start touching the left foot more. It appears that the left foot has got a lot of catching up to do.

StPeter-feet

Always keep on learning…

If you enjoyed this post, you can read more here.

In case you missed it, my last post was Seneca’s “On Shortness of Life”.

Seneca’s “On Shortness of Life”:

Time- Life is Long

Lucius Seneca (4 BC- AD 65) was a Roman Stoic philosopher and statesman. He was Emperor Nero’s tutor and unfortunately was forced by the emperor to take his own life. One of Seneca’s famous works is “On Shortness of Life”, a collection of letters and essays he wrote. Seneca’s ideas and thoughts on time gel very well with the concepts in Toyota Production System, and are still appropriate today.

There are two concepts that stuck out to me in reading the collection “On Shortness of Life”, and these both have the underlying theme of “personal time”. The first concept is about learning the value of personal time. Seneca said;

  • I am always surprised to see some people demanding the time of others and meeting a most obliging response. Both sides have in view the reason for which the time is asked and neither regards the time itself — as if nothing there is being asked for and nothing given. They are trifling with life’s most precious commodity, being deceived because it is an intangible thing, not open to inspection and therefore reckoned very cheap — in fact, almost without any value.
  • Nobody works out the value of time: men use it lavishly as if it cost nothing… We have to be more careful in preserving what will cease at an unknown point.

Along the same vein, the second concept is about productivity and improving productivity by spending your time wisely. People often complain about “not having enough time”. Seneca said;

  • It is not that we have a short space of time, but that we waste much of it. Life is long enough, and it has been given in sufficiently generous measure to allow the accomplishment of the very greatest things if the whole of it is well invested.
  • Life is long if you know how to use it.

The Value of Time in the Toyota Production System:

One of the core themes in the Toyota Production System is time – respecting other’s time and reducing the time spent in getting the product in to the customer’s hands from the factory floor. In a similar vein to Seneca’s view on the value of time, Eiiji Toyoda, a strong supporter of Taiichi Ohno, said;

  • A person’s life is an accumulation of time – just one hour is equivalent to a person’s life. Employees provide their precious hours of life to the company, so we have to use it effectively; otherwise, we are wasting their life.

This is a strong statement as Michel pointed out in his post, and it exemplifies the idea of Respect for People. Respect for People is about respecting the person’s time – not allowing him to squander it away on non-value adding activities. Wasting others’ time is a cruel activity.

Taiichi Ohno has said the following about productivity;

Measure your performance based on productivity and not by how busy you are.

Ohno’s first challenge to anybody on the floor was to find a way to get the job done with fewer operators. I should point out that Ohno never wanted to get rid of the operators. His view was that every operation or process is full of waste and this leads to operators being engaged in non-value adding activities. Being busy and getting things done are not always the same.

Similar to Seneca, Ohno pushed the supervisors and operators to use their time well and find ways to eliminate waste. It was not about working longer or bringing in more people to get the job done. It was about eliminating the waste in the operation – thus increasing the value of the operation. Toyota challenged every employee to view their production system as the Thinking Production System. This challenges people to spend their time wisely and not squander it. It is about knowing how to wisely use time in your life.

These two ideas align very well with the two pillars of the Toyota Way;

  1. Respect for People – value other’s time
  2. Continuous Improvement – learning how to use time wisely

Final Words:

I will finish off with an Ohno story that clearly shows an appreciation for others’ time (source: Pascal Dennis);

Taiichi Ohno was visiting a supplier’s plant in the early 1950’s. He spent his time observing the operators on the floor. He observed one particular operator on a machine. The operator stood in front of the machine, watching it. Ohno observed him for a few cycles of the machine.

He then asked the operator, “How often does this machine break down?”

“Never”, the operator replied.

“So what do you do all day”, Ohno continued.

“Well, I watch this machine, Ohno-san”, was the response.

“So you watch this machine all day, and it never breaks down?”

“Yes”, the operator responded, “that is my job.”

“What a terrible waste of humanity”, Ohno exclaimed to himself.

Always keep on learning…

In case you missed it, my last post was The Colors of Waste.

The Colors of Waste:

dr who

Doctor Who, a British TV show started in 1963, is the longest running Science Fiction show today and I am a big fan. There is a cool gadget in the Whovian Universe called the “Perception Filter”. This is a gadget that renders something unnoticeable. It does not make it invisible like the “Invisible Cloak” in Harry Potter’s world. It just alters your perception so that you do not pay attention to it. As one of the characters said in the show;

“I know it is there but I do not want to know it is there.”

This is a brilliant concept and I love how it applies to Lean as well. You can eliminate waste only when you start to see waste. Ohno categorized waste in to seven buckets and this makes it easier for us to “see” waste. When mass production was the norm and inventory was considered to be an ideal thing to have, Ohno was able to “see” it for what it truly was – a waste. It was almost as if there was a perception filter around the waste that nobody wanted to truly see it for what it really was.

The first step of people development in TPS is to train them to see waste. Ohno famously did this through his “Ohno Circle” – a hand drawn chalk circle on the factory floor in which the supervisor or manager was made to stay in until he started to see the waste that Ohno was seeing. This act of observation was breaking down the “perception filters” so that the waste was made visible. Once the waste is seen, the second step of people development is to put countermeasures in place while completely eliminating the waste by fixing the root cause.

Homer’s Wine Dark Sea:

There is a great Radiolab podcast called “Colors”. This podcast asked the question – To what extent is color a physical thing in the physical world, and to what extent is it created in our minds? The podcast talked about William Gladstone, a famous British politician (1809-1898) who later became Prime Minister. Gladstone was the first to notice that in the famous Greek author Homer’s works, there were many discrepancies regarding colors. Homer described the color of sea as “wine-dark”, honey as “green”, and sheep as “violet”. Gladstone came to the conclusion that the Greeks were color blind! Perhaps a better explanation would be that there was only a limited vocabulary when it came to colors in the ancient world. They had to explain multiple colors using the same words. The interesting question is whether or not having a specific word for a color acts as a “perception filter” – you know it is there but you do not want to see it.

Jules Davidoff, a researcher, went to Namibia to study the Himba tribe on their abilities to perceive different colors. A similar study was part of the 2011 BBC documentary called “Do you see what I see?” Himba tribe does not have a separate word for “blue”. Their “blue” is part of the word for the color “green”. The Himba tribe took a long time to distinguish between a quite striking blue square from other green squares. This is because they did not have a word for that specific color of blue. They could not perceive it immediately as being different from the other green squares.

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In another experiment, the Himba people were asked to distinguish between very similar shades of green, and they were able to quickly point out the odd color square because they had a separate word to distinguish that characteristic of shade. This task would be very difficult for others because all of the squares were “light green”. Thus our brains would not be able to immediately perceive the different square. Try this test for yourself. Can you pick the odd color out?

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The right answer is below.

3

Final Words:

It may not be necessary that we have a word for each waste. We should also make effort to understand it. This can only be done by going to the Gemba, and observing. We become more perceptive to the different wastes only through the regular practice of observation at the Gemba.

I will finish off with a Zen story attributed to David Foster Wallace.

“..There are these two young fish swimming along and they happen to meet an older fish swimming the other way, who nods at them and says “Morning, boys. How’s the water?” And the two young fish swim on for a bit, and then eventually one of them looks over at the other and goes “What in the world is water?”

Always keep on learning…

In case you missed it, my last post was Naikan and Respect for People.

Naikan and Respect for People:

Naikan

One of the important themes in Lean or Toyota Production System is “Hansei”. “Hansei” is translated as self-reflection and is a form of acknowledging that there is room for improvement. I have written about it here. Another term for self-reflection in Japanese is “Naikan”, which means “inside looking” or “introspection”. Naikan is also a form of meditation that was popularized by Ishin Yoshimoto, a Japanese businessman and a devout Buddhist of the Jodo Shinshu sect in Japan. He developed Naikan based on Mishirabe, an intense form of meditation. His goal was to make the practice suitable for the general populace.

Naikan is based on three questions;

  1. What have I received from others/a specific person?
  2. What have I given to others/a specific person?
  3. What troubles have I caused others/a specific person?

Yoshimoto purposefully eliminated the question – What troubles have others/a specific person caused me? The first question forces us to acknowledge that we have benefitted from others. The second question makes us aware of how we have responded. The third question makes us accountable for our actions.

Respect for Others:

Naikan increases our awareness of interconnectedness with others in this world. The theme of harmony and interconnectedness is very strong in Japanese culture. The heart of Naikan is to nurture gratitude and compassion – which aligns really well with the concept of Respect for People in lean. The biggest offense in lean is to waste others time through non-value adding activities. Our mindset puts us in the center of the world and creates stories where we are always right or why others cause problems. Naikan challenges this and gives us a chance to put on a “corrective lens”.

An Example:

At the end of each day, I can focus on a specific coworker X and ask the following questions;

  1. What have I received from X today? I can think about the interactions I had with X and the “things” either material or nonmaterial I received. There is no focus on judging the person. This is an opportunity to feel grateful.
  2. What have I given to X today? Again, the things can be either material or nonmaterial. I am not judging whether the things are good or bad. I am just creating an inventory of my contributions.
  3. What troubles have I caused X today? This is an opportunity for me to put myself in X’s shoes and examine my actions today.

With all three questions, I can now reflect on how I feel, and what I need to change or improve. This helps me to get out of the view of myself as a helpless victim, and appreciate others around me.

I will finish off with a Zen story about respect;

 Wealthy patrons invited Ikkyu to a banquet. Ikkyu arrived dressed in his beggar’s robe. The host, not recognizing him, chased him away. Ikkyu went home, changed into his ceremonial robe of purple brocade, and returned.

With great respect, he was received into the banquet room.

There, he put his robe on the cushion, saying, “Evidently you invited the robe since you showed me away a little while ago,” and left.

You can learn more about Naikan here.

Always keep on learning…

In case you missed it, my last post was Changing the Game – An Olympic Story.

Changing the Game – An Olympic Story:

rings

It is the Olympics season right now. One of my favorite stories about the Olympics is about an underdog from Oregon, USA named Dick Fosbury. Fosbury won the gold medal for the High Jump in the 1968 Mexico City Olympics. In those days, there were only a few different styles used for jumping. The main one was called the “Western Roll” where the athlete jumps forward with his face downward. Another style was called the “Scissors”, the oldest style of High Jump. This is where the athlete ran toward the bar and moved the legs in a “scissor” fashion to clear the bar. Fosbury chose the Scissors to be his style. His High School coach asked him to stop using the Scissors and to use the “Western Roll”. The Western Roll was the norm in those days and was used by the star athletes. Fosbury found no success with this. He was called the worst High Jumper in his school. He was getting frustrated, and intuitively he came up with a style that was not seen before. Rather than running straight and rolling “forward”, he ran in at an angle and jumped “backwards” which allowed him to move the bottom part of his body away from the bar. In his words;

“I take off on my right, or outside, foot rather than my left foot. Then I turn my back to the bar, arch my back over the bar and then kick my legs out to clear the bar.”

Fosbury

He was able to jump higher and higher with his method. The coach was not sure about the method, and even questioned whether the method was legal. He cautioned Fosbury that he was going to hurt his back. In those days, the athletes jumped into a big pile of saw dust. As luck would have it, Fosbury’s school installed a soft spongy landing pad at that time enabling him to perfect his style.

Fosbury went on to compete in the 1968 Olympics. As 80,000 spectators watched closely, Fosbury rocked back and forth, talking to himself and gaining confidence. It was also interesting to note that Fosbury wore different colored shoes. Fosbury slowly started running toward the bar and did what became to be known as the “Fosbury Flop”. He cleared 7 feet 4 1/4 inches to win the gold medal. His method was counterintuitive at that time. U.S. Olympic Coach Pat Jordan considered the Fosbury Flop to be dangerous and warned that it would “wipe out an entire generation of high jumpers because they will all have broken necks”. But the method was proven to be quite effective and the world of High Jump changed after that. Everybody started imitating him and improving their performance. Today the Fosbury Flop is considered to be the norm. All world record holders since 1980 used the Fosbury Flop to achieve their best performances.

Looking back, the scientists are able to explain that the Fosbury Flop is the ideal method for the high jump. The athlete is able to manipulate his center of gravity through this method to perform much higher (no pun intended) than any other method. Although Fosbury had an Engineering background, he came upon the method by accident. He was making the method work with his tall stature. His frustration with the standard methods of the day led him to find a new method.

Corollary in the Lean World:

The best form of kaizen happens when you are extremely dissatisfied with the current set of standards or if you are extremely lazy and want to find a better way of doing things. The spirit of kaizen is simply the thinking that there is always a better way of doing things. Fosbury was extremely dissatisfied with the methods in his days. In his words;

My assignment was to get over that damn bar. I was bound and determined not to quit. But I had to do something different.”

He knew that there was a better way and he found it. He explained that it was an iterative process. Once the method was proven, everybody wanted to copy it. Fosbury continued;

That day I was not trying to change the world. I was just trying to get over the bar.”

This is an important lesson for the Lean Leaders.

In a similar vein, Toyota started the Toyota Production System as a means to catch up with Germany and America. After the Second World War, Toyota realized that the productivity of the Japanese workforce was much less than their German and American counterparts. They tried to learn the norms of the day by visiting foreign manufacturing plants. But they came up with counterintuitive ways to achieve their goal slowly and steadily. They rearranged their factories to achieve better flow. They limited their work-in-process. They reduced the lot sizes and found ways to perform quick changeovers. For the painting operation, Toyota started using a paint cartridge system so that they can maintain small lot sizes. Toyota’s methods gained the attention of the world through the oil crisis in the 1970’s. Their process, Toyota Production System, became their Fosbury Flop which everybody wanted to emulate.

You can watch the Fosbury Flop performed by Dick Fosbury below.

Always keep on learning…

In case you missed it, my last post was Buy the Mountain Side.

Buy the Mountain Side:

horyuji

I enjoy learning about Japanese culture. I recently learned about the Horyuji Temple in Japan. The temple was founded in AD 607. This is said to be the oldest standing wooden structure in the world. This temple was completely restored over a span of 51 years by the Nishioka family and was completed by Tsunekazu Nishioka in 1985. In an interview given in 1985, the master carpenter Nishioka shared a great lesson.

When building a temple, don’t buy trees, buy a mountain side. He explained this as an unwritten principle given to him by his ancestors. He explained that a temple’s wood should come from a single location such that the wood can be positioned in the same orientation as the original trees – beams from the trees from north side of the mountain should go on the north side of the temple, and so on.

Each tree, shaped by its soil and decades of wind and rain, has a unique personality, artisans say. The builder, then, must understand and exploit these traits. Trees twisting slightly to the right should be used in conjunction with those twisting left, so that in the end the sum of the forces is zero.

This is a profound thought, and this applies to Teamwork. Everybody in a team works together and brings out the best in themselves and the team. Teamwork is a section of the “Respect for People” pillar of the Toyota Way 2001. In the Japanese culture, the sense of harmony is an important aspect. There is a strong effort to work together. Toyota was able to bring this regional attribute across the globe through Toyota Way 2001. Toyota strengthens their employee base through continuous mentoring and involvement. A team succeeds only when everyone understands the common goal and works collectively towards it. Toyota is able to achieve this and the end result is minimal resistance in their pursuit towards True North.

In an interview in 2007 with Yuki Funo, the chairman and CEO of Toyota Motor Sales USA, Funo also discussed the importance of teamwork with the supplier base. Toyota was entering into a new relationship with an axle supplier. The supplier was flabbergasted when Toyota awarded the contract to the supplier without any discussion about prices. The contract was awarded strictly based on the supplier’s processes and quality review. The supplier was not used to that.

“Toyota’s thinking based on the Toyota Way is teamwork with suppliers. This teamwork is going to be a long-lasting relationship. Price is only one element. Trust is a more important element. The relationship is a sharing concept, and should always be win-win. Price is important, too. But trust is perhaps more so.”

“In the church when you get married, the priest or minister doesn’t ask each partner how much each will get from the other in terms of money. You’re asked about how well you get along. What is your commitment to one another? Now, in real-life situations, some companies practice this, and some don’t.”

Final Words:

Tsunekazu Nishioka’s advice is perhaps the best advice I have heard about Teamwork – Everybody aligned in the right direction resulting in optimum results. There is a strong undercurrent of systems thinking in this. I will finish with a story I heard about 3 electricians who were working on the Apollo spacecraft:

A reporter was watching the three electricians work. He watched them intently for some time and asked each person what they were doing.

“I am inserting transistors in to circuits”, said the first person.

“I am soldering this wire”, said the second person.

“I am helping to put a man on the moon”, said the third person.

Always keep on learning…

In case you missed it, my last post was Hot Dog!

Hot Dog!

hot dog

One of my favorite quotes from Eiji Toyoda, former President of Toyota, is;

“Don’t think mechanically. Even a dry towel can produce water when ideas are conceived.”

Eiji was talking about Kaizen. Toyota talks about “There is always a better way”. This is the spirit of kaizen…reaching higher and challenging ourselves to find a better way in everything we do… every single day.

I recently relistened to a Freaknomics podcast called “A Better Way to Eat”. In the podcast, the host Stephen Dubner talked with Takeru Kobeyashi, a Japanese competitive eater now living in America. When Kobi, as he is called by his fans, came into the field, the world record was 25 and 1/8th hot dogs in 12 minutes. Kobi blew the record out of water with his first appearance in the Nathan’s Hot Dog Eating Contest, held every July Fourth on Coney Island in New York. Kobi ate 50 hot dogs in the same amount of time, almost doubling the record. The contest has been going on for over 40 years and Kobi completely broke the paradigm. Many people were in denial and some even accused Kobi of doping.

In Dubner’s opinion, Kobi looked at the problem differently thus changing the field of competitive eating forever. The question that others were tackling was – how can I maximize the number of hot dogs I eat? The question that Kobi looked at was – how can I make one hot dog easier to eat?

Putting my Lean glasses on, this made me think about the mass production versus one-piece flow production paradigm. The thinking at that time was to simply eat more hot dogs without analyzing the process. Kobi, however focused on eating one hot dog and making that process easier. Kobi researched the sport and came up with several strategies that gave him a superior edge over the competition. Some of his strategies were to split the hot dog into two and eat with both hands; and the other was to dunk the bun into water, squeeze it into a ball and gulp it down. The splitting of the hot dog came to be known as the “Solomon Method” after the story of King Solomon who settled a maternity dispute by saying that he would cut a baby in half. Several competitors started copying Kobi’s strategies and were able to double their eating intake resulting in improved performances.

In the podcast, Kobi gave the following advice about breaking the more than 40 year old artificial barrier;

I think the thing about human beings is that they make a limit in their mind of what their potential is. They decide I’ve been told this, or this is what society tells me, or they’ve been made to believe something. If every human being actually threw away those thoughts and they actually did use that method of thinking to everything the potential of human beings is great, it’s huge, compared to what they actually think of themselves. That is a factor that…If everyone could use it for everything, everything could be much better.

Final Words:

There is a similar lesson from Jesse Itzler, author of Living with a SEAL: 31 Days Training with the Toughest Man on the Planet. The lesson is as follows;

When your mind is telling you you’re done, you’re really only 40 percent done.

Always keep on learning…

In case you missed it, my last post was Toyota, The Green Tomato.

Toyota, the Green Tomato:

greenTomato

Toyota is referred to as the #1 car manufacturer in the world today. Toyota sold 10.15 million vehicles worldwide in 2015 and remained the world’s top selling carmaker for the fourth straight year. I recently came across an interesting metaphor depicting Toyota that I have not heard used before. The book “Extreme Toyota” documented an interview with Jim Press, former President of Toyota Motor North America, in which he said that Toyota wants to be a green tomato. His point was as follows;

“Green tomatoes know their futures are still ahead of them, while red tomatoes quit growing”.

One of the authors of the book, Hirotaka Takeuchi, explained this further by saying that Toyota sees itself as always growing, and always incomplete. This way, Toyota accepts that there is room for improvement, and that “tomorrow will be better than today”.  Hirotaka used the working title of the book as “The Incomplete Company”.

The metaphor of a “green tomato” is beautifully deep and underlines the idea that being complacent is bad. Toyota has become the number one car company in the world. However, seeing itself as the top company is akin to being like the red ripe tomato which would soon fall off and rot. This same idea is repeated by the former President, Katsuaki Watanabe;

“At the very instant we become satisfied, at the very moment we think that the status quo is good enough, that’s when we start to decline.” He continued, “We’re still not there. There are a lot of things we need to do.”

Final Words:

Being complacent is being ignorant and being in denial. Being complacent urges you to remain in your comfort zone. Any new information that indicates that something is wrong does not get registered. As one of my wise friends once told me, once you are complacent, you get busy trying to put up the outward appearance that everything is fine. You create a picture in your mind that everything is great and you hold on to it. The more things that go wrong, the stronger you hold on to your ideal image and continue to be in denial. Be the green tomato, and think of yourself as “still a little more to go”.

I will finish this post with a great Zen Koan by the 1st century Zen master Linji Yixuan. He said;

“When you meet Buddha on the road, kill him”.

There is a little shock factor to this koan. But once you go deeper, there is a beautiful and profound lesson in this. The road is interpreted as your journey in search of enlightenment. The Buddha in the koan is our own idea of perfection and enlightenment. And if you think that you have attained enlightenment, you surely have not attained enlightenment. You have to “kill” that thought, and stay incomplete. Be like a green tomato.

Always keep on learning…

In case you missed it, my last post was Information at the Gemba.

Information at the Gemba:

Info

Uncertainty is all around us. A lean leader’s main purpose is to develop people to tackle uncertainty. There are two ways to tackle uncertainty; one is Genchi Genbutsu (go and see) and the other is the scientific method of PDCA. Claude Shannon, the father of Information Theory, viewed information as the possible reduction in uncertainty in a system. In other words, larger uncertainty presents a larger potential for new information. This can be easily shown as the following equation;

New Information gain = Reduction in Uncertainty

Shannon called the uncertainty as entropy based on the advice from his friend John Von Neumann, a mathematical genius and polymath. The entropy in information theory is not exactly the same as the entropy in Thermodynamics. They are similar in that entropy is a measure of a system’s degree of disorganization. In this regard, information can be viewed as a measure of a system’s degree of organization. Shannon recalled his conversation with Von Neumann as below;

“My greatest concern was what to call it. I thought of calling it ‘information’, but the word was overly used, so I decided to call it ‘uncertainty’. When I discussed it with John von Neumann, he had a better idea. Von Neumann told me, ‘You should call it entropy, for two reasons. In the first place your uncertainty function has been used in statistical mechanics under that name, so it already has a name. In the second place, and more important, nobody knows what entropy really is, so in a debate you will always have the advantage.”

I loved the encouragement from Von Neumann that Shannon would have an advantage in a debate since “nobody knows what entropy really is”.

In this post, I am not going into the mathematics of Information Theory. In fact I am not even going to discuss Information Theory but the philosophical lessons from it. From a philosophical standpoint, Information Theory presents a different perspective on problems and failures at the gemba. When you are planning an experiment, and things go well and the results confirm your hypothesis, you do not learn any new information. However, when the results do not match your hypothesis, there is new information available for you. Thus, failures or similar challenges are opportunities to have new information about your process.

There are seven lessons that I have and they are as follows;

  • Information Gain ≠ Knowledge Gain:

One of the important aspects from the view of the information available at the Gemba is that information does not translate to knowledge. Information is objective in nature and consists of facts. This information gets translated to knowledge when we apply our available mental models to it. This means that there is potentially a severe loss based on the receiver. A good analogy is Sherlock Holmes and Dr. Watson at the crime scene – they are both looking at the same information available, but Holmes is able to deduce more.

  • Be Open:

When you assume full knowledge about a process, you are unwilling to gain knowledge from any new information available. You should be open to possibilities in order to welcome new information and thus a chance to learn something new. Sometimes by being open to others viewpoints, you can learn new things. They may have a lot more experience and more opportunities for information than you may have.

  • Go to the Gemba:

The majority of times, the source of information is the gemba. When you do not go to the source, the information you get will not be as pure as it was. The information you get has been contaminated with the subjective perspectives of the informer. You should go to the gemba as often as you can. The process is giving out information at all times.

  • Exercise Your Observation Skills:

As I mentioned above in the Holmes and Watson analogy, what you can gain from the information presented depends on your ability to identify information. There is a lot of noise in the information you might get and you have to weed out the noise and look at the core information available. One of my favorite definitions of information is by the famous Cerbernetician Gregory Bateson. He defined information as “the difference that makes the difference.” The ability to make the difference from the information given depends mostly on your skill set. Go to the Gemba more often and sharpen your observation skills. Ask “For what Purpose” and “what is the cause” more often.

  • Go Outside Your Comfort Zone:

One of the lessons in lean that does not get a lot of attention is – “go outside your comfort zone”. This is the essence of Challenge in the Continuous Improvement Pillar of the Toyota Way. When you stay inside your comfort zone, you are not willing to gather new information. You get stuck in your ways and trust your degrading mental model rather than challenging and nourishing your mental model so that you are able to develop yourself. Failure is a good thing when you understand that it represents new information that can help you with understanding uncertainties in your process. You will not want to try new things unless you go outside your comfort zone.

  • Experiment Frequently:

You learn more by exposing yourself to more chances of gaining new information. And you do this by experimenting more often. The scientific process is not a single loop of PDCA (Plan-Do-Check-Act). It is an iterative process, and you need to experiment frequently and learn from the feedback.

  • Challenge Your Own Perspective:

The Achilles’ heel for a lean leader is his confirmation bias. He may go to the gemba more often, and he may experiment frequently. Unless he challenges his own perspective, his actions may not be fruitful. My favorite question to challenge my perspective is “What is the evidence I need to invalidate my viewpoint right now, and does the information I have hint at it?” Similar questions ensure that the interpretation of the information you are getting is less tainted.

I will finish off with a funny story I heard about Sherlock Holmes and Watson;

Sherlock Holmes and Dr. Watson decide to go on a camping trip. All the way to the campsite, Holmes was giving observation lessons to Dr. Watson and challenging him. After dinner and a bottle of wine, they lay down for the night, and go to sleep.

Some hours later, Holmes awoke and nudged his faithful friend.

“Watson, look up at the sky and tell me what you see.”

Watson replied, “I see millions of stars.”

“What does that tell you?” Holmes asked.

Watson pondered for a minute.

“Astronomically, it tells me that there are millions of galaxies and potentially billions of planets.”
“Astrologically, I observe that Saturn is in Leo.”
“Horologically, I deduce that the time is approximately a quarter past three.”
“Theologically, I can see that God is all powerful and that we are small and insignificant.”
“Meteorologically, I suspect that we will have a beautiful day tomorrow.”
“What does it tell you, Holmes?” Watson asked.

Holmes was silent for a minute, then spoke: “Watson, you idiot. Someone has stolen our tent!”

Always keep on learning…

In case you missed it, my last post was The Pursuit of Quality – A Lesser Known Lesson from Ohno.