Gemba Academy

The Secret Lives of Toyota Term Employees, Episode 2

By Jon Miller - September 6th, 2007

How to Pass the Term Employee Job Interview at Toyota The website “The New – Ask the Term Laborer Porsche” (新・期間工ポルシェに訊け) offers a fascinating glimpse into the secret lives of Toyota term emplo

Kaizen Song: It’s a Long Way to the Top (Teaching Takt, Flow, Pull)

By Jon Miller - September 5th, 2007

By Brad Schmidt Here’s a little back-to-school rock ‘n’ roll. It’s a Long Way to the Top (Teaching Takt, Flow, Pull) [To the tune of It’s a Long Way to the Top (If You Wanna Rock ‘n’ Roll) by A

Getting Started with Lean in the Office

By Jon Miller - September 3rd, 2007

One of the most common misconceptions about doing Lean in the office is that there is a different set of Lean tools for the office. We hear “What symbols should we use for value stream mapping in an engineering process?” or

Autonomous Maintenance in the Office

By Jon Miller - September 2nd, 2007

We are going through some design change tests at the Gemba blog as long-time readers may have noted. While testing the various functions and features to send back fix requests to our developer, I came across some reader comments and qu

Management Improvement Carnival #18

By Ron Pereira - September 2nd, 2007

The Management Improvement Carnival is one of my favorite aspects of John Hunter’s Curious Cat blog. John asked me to host the carnival this month and I gladly accepted. So without further delay here are some of my favorite

Lean Sigma Supply Chain

By Jon Miller - August 31st, 2007

Lean Sigma Supply Chain is a blog full of thoughtful, pithy posts as well as the occasional deep dive into lean logistics or lean distribution know-how. Today’s post about 50 things to do to free up warehouse space is a grab bag

Game on!

By Ron Pereira - August 31st, 2007

I grew up watching Ohio State play football. I suppose I was watching them play as a young boy in Greenville, Ohio before I even knew what football was. My mom once told me, “You can take the boy out of Ohio (I live in Texas now), bu

Top 10 Books on Lean Thinking

By Jon Miller - August 30th, 2007

Here is a highly subjective list of the top 10 books on Lean thinking. Toyota Talent: Developing Your People the Toyota Way by Jeffrey Liker and David Meier This book has the benefit of being new, and providing very practical and relev

Fun with Confidence Intervals – Part 2

By Ron Pereira - August 30th, 2007

Last night we began our discussion on confidence intervals. Specifically, we talked about the difference between population and sample parameters and how they play a major role in understanding what a confidence interval is. Tonight I

The Toyota Production System is Practice, Not Theory

By Jon Miller - August 29th, 2007

Pete Abilla from the Shmula blog, recently commented on one of our blog articles Is the Theory of Constraints (TOC) a Theory? He said: During my short time at Toyota, I learned this lesson well: we were always encouraged to “try

Fun with Confidence Intervals – Part 1

By Ron Pereira - August 29th, 2007

If I said the words “confidence intervals” would you know what I meant? What if I also asked if you could calculate them? If you answered no to either one of these questions I assure you will be able to answer yes by end of this tw

5 Decision Making Styles

By Ron Pereira - August 28th, 2007

Let’s suppose you are a parent and decide to ask your kids to help you make an important family decision. After careful consideration your kids share their thoughts with you only to learn the decision had already been made and

Why You Need A Tatakidai

By Jon Miller - August 28th, 2007

When people say to me “We don’t need no more stinkin’ Japanese words in our Lean vocabulary,” I don’t argue. Most of us aren’t using all of the ones we’ve got anyway. Why acquire knowledge you

Increasing Return on Net Assets (RONA) with Lean & Six Sigma

By Ron Pereira - August 27th, 2007

The business metric RONA (Return on Net Assets) is used by many companies in order to gauge how well they turn their assets into income. I am no accountant but do know there are a few ways to calculate RONA. For the sake of this arti

The Secret Lives of Toyota Term Employees, Episode 1

By Jon Miller - August 26th, 2007

Kaizen and respect for people. These are the words under which Toyota presents itself as a company that builds cars by building people. Yet this is the ideal, and we know that there is always a gap between reality and the ideal. What i

Lean Sushi

By Ron Pereira - August 26th, 2007

I came across a fun story of how a sushi shop uses lean principles to its advantage. Kura Zushi, operated by Kura Corp., is the third-largest player in the industry. What sets it apart is its just-in-time production system, similar to

Target, Actual, Please Explain

By Jon Miller - August 24th, 2007

I learned some important lessons today. One which I will share is to never compromise when it comes to placing visual status boards on the shop floor. Visual status boards promote problem solving and kaizen by exposing problems. There

Kaizen Song: We Demand Visual Controls

By Jon Miller - August 22nd, 2007

We Demand Visual Controls (to the music of David Bowie’s “The Man Who Sold the World”) A fax was on my desk, it spoke of promises “My order isn’t there, hey when was it sent?” Which came as some surprise, logged in and

Teaching with LEGO

By Ron Pereira - August 22nd, 2007

I am passionate about teaching people the principles of lean and six sigma but this passion is nothing compared to how badly I want my children to learn and grow into well rounded/successful citizens. I often joke about how I intend to

Descriptive Statistics – Part 2

By Ron Pereira - August 21st, 2007

Last night in part 1 of this series we began our discussion of descriptive statistics by introducing the three measures of central tendency – the mean, median, and mode. As promised tonight we switch gears and are all about var

Is Your Lean Deployment “Made to Stick?”

By Jon Miller - August 21st, 2007

Mark Rosenthal is The Lean Thinker who connects the ideas from the book Made to Stick to visual controls used on the shop floor in a Lean factory. Mark argues convincingly for having “Sticky” Visual Controls in an article posted ye

Descriptive Statistics – Part 1

By Ron Pereira - August 20th, 2007

Tonight we are starting a two part series on descriptive statistics. Yeah, I know, many of you are likely having nasty flash backs of some professor with bad breath but by the end of this series I hope to make all those bad thoughts

The Essence of Shop Floor Management

By Jon Miller - August 20th, 2007

Chris Schrandt is a Gemba guy from Toyota who has wealth of experience in quality management and TPS. He had several great quotes during a problem solving class today, and this one about exposing problems struck me as particularly wort

iSixSigma Editorial Advisory Board

By Ron Pereira - August 19th, 2007

I am very honored (and humbled) to announce that I have accepted an invitation to sit on the iSixSigma Magazine editorial advisory board. In this role I will have the opportunity to offer feedback and ideas to what I believe to be

Is the Theory of Constraints (TOC) a Theory?

By Jon Miller - August 18th, 2007

The tagline Theory of Constraints Exposed in an IndustryWeek article from March of this year got me thinking about TOC. Not a bad article by the way, although I’m still waiting for the Lean-TOC software system sales pitch shoe to

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