Gemba Academy

Value Stream Mapping Overview

By Ron Pereira - February 8th, 2008

One of, if not the single most powerful lean tool available to us is value stream mapping (VSM). The reason it’s so powerful is because of its relevancy. You see, it doesn’t matter if you are an accountant who sits behind a

101 Kaizen Templates: Changeover Analysis

By Jon Miller - February 7th, 2008

There are many common non-lean behaviors such as local optimization, batch work, and building up inventory. Creating WIP lengthens cycle time, worsens quality, builds up barriers between processes and people contributes to late deliver

Long Live the King (Cash)

By Ron Pereira - February 7th, 2008

If you are involved with a for-profit business in any way please remember one thing – cash is king. Of course respecting people is absolutely critical. But cash pays the bills. It buys things. It pays salaries. So without money in

Management by Kaizen Events

By Jon Miller - February 6th, 2008

Mark Graban made the point today in the Lean Blog that kaizen events are not enough. He agrees with another lean healthcare article that by themselves, the rapid improvement events of 3 to 5 days in duration are not sufficient to achie

Schofield Media Group Announces Acquisition of iSixSigma

By Ron Pereira - February 6th, 2008

Big news yesterday from Michael Cyger, owner of the extremely popular iSixSigma brand. I am pleased and excited to announce that CTQ Media, owner of the publishing brands including iSixSigma, Real Innovation, BPM Enterprise and Sourcin

The Never Ending Pursuit of Wisdom

By Ron Pereira - February 5th, 2008

Let no one deceive himself. If any one among you considers himself wise in this age, let him become a fool so as to become wise (1 Cor 3:18). Wisdom is a mysterious thing and something, I contend, worth our full attention. You see, I

101 Kaizen Templates: Takt Time Calculator

By Jon Miller - February 4th, 2008

A reader pointed out that the takt time for posting the 101 kaizen template has exceeded. It is true that we have not been hitting a consistent 1 template per 3.5 days. To meet our goal for 101 of these by the end of 2008 we will need

Exploring the “Respect for People” Principle of the Toyota Way

By Jon Miller - February 3rd, 2008

Author, Professor and lean thinker Bob Emiliani has made another important contribution with his new book Practical Lean Leadership. I had the pleasure of reviewing and giving editorial input on this fine book and would recommend it fo

Just Do It

By Ron Pereira - February 2nd, 2008

“Talk doesn’t cook rice.” -Chinese Proverb While planning, checking, and acting/adjusting are of course crucial elements of the PDCA cycle I sometimes feel as though the “do” element is under-utilized. In a similar way,

The Secret Lives of Toyota Term Employees, Episode 6

By Jon Miller - January 31st, 2008

Tomorrow is Creative Idea Suggestion Submission Day What happens after a term employee at Toyota becomes a regular employee? Is this the happy ending when the assembly line workers finally feel the warm embrace of President Watanabe? D

JIT and Jidoka are Useless…

By Ron Pereira - January 30th, 2008

Yes, the two pillars of the Toyota Production System – JIT and Jidoka – are absolutely worthless… if you don’t respect people. You see, in my opinion, anyone who tries hard enough and gets support from more ex

Breaking Down Barriers to Continuous Flow

By Jon Miller - January 28th, 2008

One way to look at lean is that it’s all about enabling the continuous flow of actions, information, materials, services and cash in such a way that these things generate of goodness, however you may define that. The theory is th

Rope Suppliers

By Ron Pereira - January 28th, 2008

J Thatcher recently asked: Here’s a question: If the student becomes the initiation point for “pull” learning, how does the instructor continue to “push” students beyond what they believed themselves capable? (And yes, I’m

Inspired at NASA

By Ron Pereira - January 27th, 2008

This past weekend my family and I went to Houston to visit some relatives. On Saturday we went to NASA. If you have never been there you need to carve out some time to make this visit. I took quite a few pictures and will try to

Sustainability, the New Buzzword. But Is It Sustainable?

By Jon Miller - January 26th, 2008

Thanks to polar ice melts, $100 per barrel oil prices, and an inevitable generational shift to people who have grown up hearing about environmental destruction arriving in positions to influence opinion, consumption and policy, sustain

101 Kaizen Templates: ECRS Worksheet

By Jon Miller - January 25th, 2008

We often talk about lean management being the elimination of all waste and non-value added. We may call it the pursuit of perfection, of a waste-free process. But what if we can’t eliminate a certain waste from a process? What to

Should we Push or Pull in Schools?

By Ron Pereira - January 24th, 2008

My good friend, and excellent blogger, Mark Graban posted an interesting article related to how a school is using continuous improvement methods to, well, improve things. For those who don’t know, Mark and I live in the same town an

What Can We Learn from Boeing's Lean Supply Chain Stumbles?

By Jon Miller - January 23rd, 2008

Not much more than a decade ago, Boeing went through a hiring binge to ramp up production, fell flat on deliveries and shed many jobs as a result. Gemba’s office is quite near Boeing’s Everett, Washington factory and the fu

Excellence is a Habit

By Ron Pereira - January 23rd, 2008

“We are what we repeatedly do. Excellence, then, is not an act, but habit.” -Aristotle I am doing my best to teach my kiddos about lean and six sigma. Since they are ages 5, 3, and 1 my instructional tactics need to be crea

Textron CEO on State of Six Sigma

By Ron Pereira - January 22nd, 2008

USA Today recently interviewed Lewis Campbell, Textron’s CEO. The questions were mainly centered on Textron’s enterprise wide deployment of Six Sigma. They asked several questions, some of them quite tough. All were answered with,

16 More Ways to See Motion Waste when Standing in the Circle

By Jon Miller - January 21st, 2008

The stand in the circle activity is a great way to train your eyes to see waste on your gemba. Finding 30 small kaizen ideas in 30 minutes, and rapidly implementing at least one of those ideas is a practical and scalable way of teachin

Has Lean or Six Sigma Changed your Life?

By Ron Pereira - January 21st, 2008

Mark Graban just posted an article about LEI’s newest book. Looks to be sort of like the Lean Lexicon but with blog-like quotes. Mark shared one of the excerpts from the book. “Lean should not have ‘changed’

101 Kaizen Templates: Minor Motion Analysis

By Jon Miller - January 19th, 2008

We’re big fans of making significant organization-wide change by involving everyone in small improvement activities every day. This is especially important for sustainability as you progress on your lean journey. As you progress

Learning to Learn

By Ron Pereira - January 17th, 2008

Lean Enterprise Institute has a book called Learning to See. It’s about how to use value stream maps to “see waste” in a new way. It’s a great book and even better book title. Go to Amazon and check it out. But I think an even

Lay First the Foundation of Humility

By Jon Miller - January 17th, 2008

I came across this great quote by St. Augustine. Do you wish to rise? Begin by descending. You plan a tower that will pierce the clouds? Lay first the foundation of humility. These words work on many levels. When corporate board rooms

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