Gemba Academy

And Now We Have “Kakushin” (sigh…)

By Jon Miller - December 8th, 2006

In the December 9, 2006 Wall Street Journal article titled As Rivals Catch Up, Toyota CEO Spurs Big Efficiency Drive the Toyota Motor Corporation President Watanabe adds another Japanese word to the Lean lexicon: kakushin. Debates coul

When the Customer Defines Value, But They Define It Poorly What Do You Do?

By Jon Miller - December 6th, 2006

If a customer says “Here’s how I want to do Lean.” and the consultant says “That’s not the right way.” and the customer says “Who’s the customer here?” and the consultant says ̶

How to Put Kaizen into Your Culture

By Jon Miller - December 5th, 2006

These are the two steps for how to put kaizen into your culture. First, communicate with your people until you have a common agreement and 100% alignment on these principles: The reason we can make our living is because we serve our cu

One-Hour Low Tech Lean Introduction

By Jon Miller - December 4th, 2006

Today was a lesson for me in just-in-time delivery of Lean training (or Lean Lean training) and also in the value of being prepared. We arrived half a day late to a distribution center where we were asked to give Lean overview training

Gemba Keiei by Taiichi Ohno, Chapter 34: The Pitfall of Cost Calculation

By Jon Miller - December 1st, 2006

In this chapter Taiichi Ohno talks about the pitfalls of using cost calculation to justify new equipment purchases and also decisions to scrap or replace equipment based on depreciation. “Whenever we need to make a decision, we e

Hansei on Hansei

By Jon Miller - November 30th, 2006

As Taiichi Ohno said “Check is hansei” when referring to the third step of PDCA. I am doing hansei on the previous blog post on the topic of hansei. I did not think deeply enough about what “hansei” means and wh

The ROI of an Open Office

By Jon Miller - November 29th, 2006

What is the ROI (return on investment) of an open office? That was a question some while back by a reader on this blog about to take the leap and convert their office to an open format. It went unanswered (apologies) and I was recently

Dilbert Rips Six Sigma

By Jon Miller - November 28th, 2006

Kent Bradley from Gemba handed me a Dilbert cartoon yesterday poking fun at Six Sigma. Here is the script: [Point-Haired Boss standing next to “SIX SIGMA” slide] Our company has decided to try something new. [Dilbert] New?

The Toyota Way is Total Company Discipline, Partial Study is GM’s Failure

By Jon Miller - November 27th, 2006

Kan Higashi was President of the NUMMI company, the joint venture between Toyota and GM, when it was started two decades ago. In the October 16, 2006 issue of Nikkei Business (a Japanese magazine) Mr. Higashi shares his insights in a s

Gemba Keiei by Taiichi Ohno, Chapter 33: The Difference Between Production Engineering and Manufacturing Engineering

By Jon Miller - November 26th, 2006

Taiichi Ohno begins the chapter by saying “We think of production engineering and manufacturing engineering as distinct things. We distinguish manufacturing engineering as the work to determine the method of manufacturing and pro

Thankful but Dissatisfied

By Jon Miller - November 25th, 2006

Reflecting on this Thanksgiving holiday, I have a lot to be thankful for but I am dissatisfied. It has been a challenging year in many ways, both personally and in business. I am thankful that there are so many problems in front of me

How to Stay Out of Trouble with Mr. Convis

By Jon Miller - November 23rd, 2006

Gary Convis is the senior vice president of manufacturing in North America for Toyota Motor Corporation. In a November 20, 2006 article in the Lexington Herald-Leader titled New Tundra Plant Just Shows that … Toyota Keeps on Truc

The Water Spider: What’s in a Name?

By Jon Miller - November 22nd, 2006

One of the things that keeps Lean manufacturing from being boring to the amateur linguist is the many odd-sounding words that make up the Lean lexicon. Kamishibai Heijunka Pareto Yamazumi Takt Andon Jidoka Kaizen Pokayoke Gemba And don

What is a Kamishibai?

By Jon Miller - November 21st, 2006

I heard the term kamishibai (紙芝居) used in the context of the Toyota Production System for the first time in 2006. It was at an LEI seminar hosted by a former Toyota manager. At the time I thought it was a gratuitous use of a Japa

Dissatisfaction: The Essence of Toyota Management and the Kaizen Mindset

By Jon Miller - November 20th, 2006

I’ve said again and again that complacency and being satisfied with the current condition are anathema to kaizen. The article in Fast Company December/January 2006 issue titled “No Satisfaction” is excellent. Here are

Top 5 Things I Learned in China Last Week

By Jon Miller - November 19th, 2006

Here are the top five things learned after a productive week in China: 1. You can’t overstate the value of respecting another’s culture I gave my rudimentary Chinese a workout this time and the results were interesting. Doo

Why Six Sigma is Essential for Kaizen Success

By Jon Miller - November 18th, 2006

Genchi gembutsu means that in a Lean organization improvement must be done at the closest point to the value-adding workplace (gemba) following the scientific method based on facts. I’ve liked genchi gembutsu and management by fa

Seeing the Lean in Milton Friedman’s Ideas

By Jon Miller - November 17th, 2006

Nobel prize winner and Chicago school free market economist and author Milton Friedman has just passed away. The impact of his ideas are huge. It ranks with the impact of the ideas of Henry Ford and Taiichi Ohno. Like Ohno and Ford, Fr

Believing You Can Get Lean Makes You Leaner

By Jon Miller - November 16th, 2006

If Lean for Toyota is “kaizen and respect for people” we need to spend some time understanding what makes people work as well as what makes kaizen work. To that end, there are some very interesting findings at the Psycholog

Kaizen of the Month at Gemba, November 2006

By Jon Miller - November 13th, 2006

Like many companies, we make a lot of improvements each month at Gemba. We don’t always think to write them down or celebrate them. We will “kaizen the kaizen” by writing them down in an effort to be more mindful of t

The Toyota Preparation System or the “Bank of Preparation”

By Jon Miller - November 9th, 2006

Toyota is great at doing what appear to be common sense things extraordinarily well. They take the time to do preparation, then execute quickly. There is a reference to this in Jeffrey Liker’s The Toyota Way where (I am paraphrasing)

Applying Lean Manufacturing to University Libraries

By Jon Miller - November 6th, 2006

Nancy Kress is the Head of Bookstacks at the University of Chicago. Nancy says in her libraryassessment.info posting on November 5, 2006: I like to tell people that what I really do is line operations management. My challenge is to man

Kaizen vs. Kaikaku

By Jon Miller - November 5th, 2006

While “kaizen” has been a familiar term in English management vocabulary for decades, “kaikaku” is more recent. Though kaizen has been widely embraced by Japanese companies for years, kaikaku was less common. Ho

Things They Say at Toyota: Being Busy is Shameful

By Jon Miller - November 2nd, 2006

Being busy is shameful. What an odd thought. It goes against the workaholic nature of most Americans and our Puritan work ethic. I can’t recall exactly where I heard this but it was definitely from one of my sensei who came from

Taiichi Ohno’s Book “Workplace Management” Returns to Print in 2007

By Jon Miller - November 1st, 2006

Almost two years ago I set out to read Taiichi Ohno’s recently reissued book Gemba Keiei (Workplace Management) in Japanese and summarize one chapter per week. My goal was to have all 37 chapters posted here by September 2005. We

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