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Many organizations use planning techniques such as strategic planning or hoshin kanri to get the direction of the company, create the plans and implement them. So what’s your Lean emphasis this year? Take our one-click quick poll and see what others are thinking. Go to our homepage and you’ll see it on the right side www.5Ssupply.com.

P.S. You can also signup for our upcoming free webinar on Value Stream Mapping: What to do before you dive in.

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5S Supply’s Year in Review

December 19, 2011

As part of any good hansei (honest reflection) and Hoshin planning we like to look back and share some of our highlights for 2011 at 5S Supply.

Jennifer & Tony at AME

Conference Sponsorship and Exhibiting – This was the first year we ever had a booth at a conference. We were a Silver Level Sponsor for the Association for Manufacturing Excellence (AME) Conference in Dallas, Texas October 25-27. If you missed it, check out our photos on Flickr 5S Supply.

5S Benchmarking Survey – we had hundreds of people participate in the most comprehensive benchmarking survey ever created for 5S. We will have “The Very Best of 5S” report coming out soon.

New Products – we continue to find outstanding new items that will help you on your lean journey. Some of our top new products include: Gauge Range, Mobile Tool Works, and Tru-Tray System.

TPM Blitz DVD – I was honored to help create the newest DVD on Total Productive Maintenance from the Society for Manufacturing Engineers (SME) and the Association of Manufacturing Excellence (AME). The TPM Blitz DVD showcases a team as they perform a four-day TPM event in a manufacturing cell.

Social Media – we continued to add to our ever growing lean community with our 5S Supply Facebook page, Twitter account, 5S Supply YouTube channel and more. Join the conversation!

As we move into 2012 we will continue to bring you the best of lean with our products and services. Some things to look forward to include:

Lean Handbook – I am a co-editor of the upcoming “Lean Handbook” from Quality Press with the launch to coincide with the American Society for Quality’s Lean and Six Sigma Conference February 27-28, 2012 in Phoenix Arizona. I will host a session on “The Lean Handbook Journey”.

More new products – We will continue to create and find the best products for you lean implementation. Stay tuned as we continue to add items to our site.

Training – of course we will continue with our ever-popular free webinars. We will also support on-site lean implementation help, training, coaching, kaizen facilitation and consulting. Our mission is to help you on your lean journey; our extensive experience will lead your organization to the next level.

So here’s to a great 2011 and an even better 2012!

All the best,

Tony

It’s pretty easy to see how Value Stream Mapping helps out in operations planning or short-term planning (one year or less time-frame). But what about using VSM for strategic or long term planning?

Here are two answers for that:

  1. Create Extended Level Value Stream Map
  2. Create Ideal State Value Stream Map

As you get better in your lean thinking, you will discover that involving your customers and suppliers is the right thing to do. Using your Extended Level VSM can help tailor your strategic long term or Hoshin plan to help improve your market position. Seeing what is important to your customers and suppliers by getting them involved in your Extended Level VSM focusing on a longer time frame (three to five years) will help build a solid strategic plan. This, of course, means getting top management from the supply chain actively involved. Another way VSM can help strategic planning is to create an Ideal State Map for a value stream. Create an ideal Future State that is about five years out. This will help determine “breakthrough” strategies as part of your strategic planning.

Some organizations are seeing the benefit of using Hoshin Kanri as their primary strategic planning and execution process. It might seem a little “chicken and the egg” to say should we have our Value Stream Maps first to help direct our planning efforts or should our planning efforts drive our maps? Well. The simple answer is “yes”. Part of Hoshin is to review previous plans including Value Stream Maps. Once a strategic vision is set VSM can help drive the right projects to help achieve the future state.

Join us for a Free Webinar – Introduction to Value Stream Mapping September 29, 2011

I had a great time at this year’s WCQ&I in Pittsburgh (although it seemed to rain the whole time – that didn’t really matter since I was inside). Here is my recap of ASQ’s leading conference.

Arriving on Sunday, I was able to take part of the Lean Enterprise Division’s annual board meeting. It was nice to see that it was well attended and productive. Many projects from the year were updated and there was an excellent discussion on how ASQ headquarters and the LED can work together to promote the premier Lean Certification that is hosted by ASQ, SME, AME and the Shingo Prize.

Monday morning’s keynote speaker Admiral (ret.) Thad Allen was an engaging speaker. I liked that he didn’t have any PowerPoint presentation and just spoke form the heart. In my mind he was in charge three of the toughest assignments anyone could have had: relief after hurricane Katrina, earthquake relief in Haiti, and the BP oil spill in the Gulf of Mexico. He talked about his experiences during these times. For more information on this and other happenings during the conference you can check out my tweets at www.twitter.com/5Ssupply or search using hash tag #WCQI11.

Monday afternoon I did a deep-dive presentation on using Hoshin Kanri’s X-matrix. This was an expansion of my article “Hoshin Promotion” in ASQ’s Six Sigma Forum Magazine last August. I wanted to show people how to work with one of the tools during Hoshin planning and how to take it to the next level.

I enjoyed my time seeing old friends and meeting new ones. I attended some great sessions on Lean related topics. One of my favorite parts was being at LED’s booth on the conference floor. It was wonderful to see all the people stop by, talking shop and passing out Lean Certification packets.

Another keynote that I attended was Barbara Corcoran (from the television show Shark Tank) who talked about lessons she learned throughout her life. She turned a $1,000 investment into a multi-million dollar real estate business. Her combination of humor and heart-felt stores engaged the audience. Check out her new book “Shark Tales”.

Once again if you want more information about the conference you can check out my tweets at www.twitter.com/5Ssupply or search Twitter using hash tag #WCQI11. I also put up some pictures on our flickr account http://www.flickr.com/photos/5ssupply.

I can’t wait to attend next year at Anaheim. Hope to see you there! – Tony

I had a great time at the Association for Manufacturing Excellence (AME) Conference last week in Baltimore. I would consider this one of the best lean conventions in the world. It would be hard to deny it when you have over 2,000 attendees and such spectacular key note speakers including Dr. John Toussaint, George Keonigsaecker, and Malcolm Gladwell. Here’s my quick review and highlights.

Hoshin Kanri Workshop

On Monday morning I taught a workshop on Hoshin Kanri (a.k.a. Policy Deployment). I appreciated the different backgrounds of the participants and the various levels of knowledge. I hope each was able to take away something that they would be able to implement when they got back to their organizations. If you would like a Hoshin overview check out my article in ASQ’s Six Sigma Forum magazine “Hoshin Promotion” or check out these items on Hoshin Kanri/Policy Deployment at 5S Supply.

5S Supply’s Partners

One of my favorite things about attending these conferences is running into old friends and making new ones. I had to chance to stop by different partners of 5S Supply to chat, talk lean and have a little fun. Check out the photos below.

Lean Enterprise Institute

(L-R Tony Manos, 5S Supply, Jane Bulnes-Fowles, Lean Learning Materials Manager, John Shook, Chairman & CEO, Rachel Regan, Director of Lean Events and Community Support, and Jon Carpenter, Finance & Administration)

I would like to thank the Lean Enterprise Institute for being my cohorts in using twitter during the conference and retweeting information to our followers. Also, I would like to announce that LEI is now offering one of the top books “The Gold Mine” in audio book (CD) form. Dr. John Toussaint (key note speaker and author) was signing his book “On the Mend” during the conference. If you are trying to apply Lean in healthcare, this is the book for you and available at 5S Supply.

Visual Workplace, Inc.

(L-R Jerry VanderLann, Tony Manos, and Rhonda Kovera)

Visual Workplace, Inc. provides 5S Supply with one of our most popular product lines – FloorMark. We carry FloorMark tape, arrows, feet, corners and more. Keep an eye out as we add more items to our website!

GBMP

(L-R: Pat Wardell, COO, Tony Manos, and Bruce Hamilton, President)

You might know GBMP from the famous “Toast Kaizen” video, but they have so much more! It was great to see Chris Martin, VP Sales & Administration along with Pat Wardell, and Bruce Hamilton. Pat and Bruce just came out with a new book “e2 Continuous Improvement System” that emphasizes “everyone, everyday”. 5S Supply will be getting this book up on our website soon; it’s sure to be a great resource. By the way, I have to give a special award or mention to GBMP for their booth as being the most creative at the show. They came right out and said it – “Waste Sucks!” but evidently it can kill to (they had a mannequin stuffed under a pile of boxes representing waste).

Taylor and Francis (CRC Press)

5S Supply & Taylor and Francis(L-R Michael Sinocchi, Senior Editor, Tony Manos, and Chris Manion, Special Sales Account Representative)

I’m almost sure everyone reading this probably has a book published by Taylor & Francis or CRC Press (formerly Productivity Press). Michael was kind enough to show me some of their newest books on Lean HR and Lean IT. Don’t worry; we’ll get them up on our website as soon as we can. T&F is a great source of books, DVDs and learning materials, that are available at 5S Supply.

The Lean Nation Radio Show with Capt. Karl

I had the pleasure to be a guest on The Lean Nation radio show back in June talking with Capt Karl about Value Stream Mapping and other things. Karl Wadensten also gave a presentation about his company’s Lean journey. He talked about the path that Vibco has taken over the years as they continually strive for continuous improvement. If you haven’t heard Capt Karl’s show, I highly recommend that you download a free podcast and listen in.

American Society for Quality (ASQ)

(L-R: Robert Damelio, Brian LeHouillier, Managing Director-ASQ, Adil Dalal)

Robert and Adil are my cohorts on the Lean Certification Oversight and Appeals (COA) Committee representing ASQ. Brian was attending meetings with the heads of AME, SME and the Shingo Prize as the four representatives of the premier Lean Certification in the world!

Society of Manufacturing Engineers (SME)

(L-R: Kelly Lacroix, Tony Manos, Tara Douglass, Professional Development)

Kelly is our “handler” for the COA. She works hard to make sure that all four groups representing the Lean Certification (AME, SME, Shingo Prize and ASQ) are forging ahead with the certification. Tara works in professional development. Not pictured was Jerome Cook who I am working with to create a new Total Productive Maintenance (TPM) DVD due out early next year.

Change Management Associates

Drew Locher has written what I would consider two of the best books on Value Stream Mapping – “The Complete Lean Enterprise” and “Value Stream Mapping for Lean Development”. Drew was the one that taught me VSM back in 2000. Drew is the principle of Change Management Associates. Since 1990, CMA has developed and delivered programs to enhance the skills and knowledge of organizations in the general subject of Operational Excellence.

I would like to thank all our supporters and I look forward to seeing everyone again at the AME Conference 2011 in Dallas, TX! 

Also, since it is the week of Thanksgiving I would like to say to all those pursing Lean “Thank You” for your efforts and differences you make in peoples’ lives everyday. Have a happy and safe Thanksgiving! – Tony

“What gets measured gets done.” – Tom Peters

I had fun working with a client last week helping them determine meaningful measures & metrics to monitor systems that were currently being developed and deployed. We talked about usual things like: 

  • think about if they are short-term, medium term or long term,
  • that it might be good to have a mix of Lean metrics like quality, cost or delivery,
  • we could use a Balanced Scorecard approach (ref: Kaplan & Norton) with financial, customer, internal processed and learning & growth,
  • Are the things we want to monitor drivers, means, or outcomes (ref: Hoshin Promotion)
  • consider the audience – who are these for? value-adders, supervisors, managers or executive management,
  • and trying to have a combination of leading, lagging and real-time measures & metrics

It’s this last bullet that the team really got me thinking. I use a baseball analogy to describe leading, lagging and real-time measures & metrics. For example, a leading indicator may be that I suspect my starting picture has at least 80 throws in his arm today (also known as ‘pitch count’). Currently he is up to 69. Based on this leading indicator, I should consider getting a relief picture ready. Another way to think of a leading indicator may be the amount of budget used so far as compared to what’s left in the project or how close we are compared to our goal (think thermometer graph for fund raising). A real-time indicator may be the ball or strike called by the umpire when the ball passes the plate or the speed of the picture’s fastball as determined by the radar gun. Lagging indicators are usually easy to see like who won the game or the box score information including runs, hits & errors. These are after the fact; they already happened.

Then it dawned on me as the team was working on their measures & metrics and asking questions if something is a leading, lagging or real-time indicator that many things depend on what you are using it for. We discussed the finer points of their measures and try to put these into context. For example, who won or lost the baseball game would normally be considered a lagging indicator (it’s over; there’s nothing we can do about it now). For the most part, I would probably agree until we started to explore other possibilities. What if that win or loss is closer to the end of the season and as a manager I have to start to make decisions about the play-offs like whether to promote someone from the farm system or consider a trade to bolster my team (or reduce salaries)? Doesn’t that lagging indicator now become a leading indicator? Think about another lagging indicator like who finished the season with the most home runs or won a golden glove? Would these possibly be leading indicators of how well they may do next season? Here’s another example, what about the ball or strike called by the umpire? When it is called, that would be a real-time indicator, but shortly thereafter wouldn’t it be considered a lagging indicator? So what time frame are we looking at?

In a lean sense, would takt time be considered a leading indicator? What about the cycle time, is that considered real-time? Would on-time delivery be considered lagging?

I think this would all be based on things like: what are you going to do with the information, what time-frame are you considering, who is your intended audience, etc.

What are you thoughts? Let me know. Thanks – Tony

P.S. If you’re at the AME Conference in Baltimore this week, look for me and let’s talk Lean.

“Before everything else, getting ready is the secret of success.” – Henry Ford

Alber Kahn - industrial architech to Henry Ford (c.1935)

As you can probably tell, I am on a kick for Hoshin Kanri lately. I think this is for a host of reasons:

  • I just had an article published in the American Society for Quality’s Six Sigma Forum Magazine called “Hoshin Promotion
  • 5S Supply is offering a free webinar covering the basics of Hoshin on Wednesday, September 23, 2010,
  • I’ll be presenting a full one day workshop Hands-on Hoshin for Everyone at the first annual Visual Workplace Summit October, 26, 2010,
  • I was selected to present a paper on Demystifying the X-Matrix at next year’s Lean Six Sigma Conference, and
  • 5S Supply is preparing to go into our planning session for next year.

People underestimate the power of preparing for their Hoshin planning session. I think many people believe that you just gather the top executives, get them off-site (preferably a place where they can play golf), sit them down for a couple of days and magically the strategic plan is created for next year. O.k., for some companies that is how it actually happens. 

But for the rest of us, getting ready for the session is critical. Here are some tips to make this process a little better.

1)      Be off-site – This sounds like a scam, but I recommend this for two reasons:

  1. It allows management to focus without interruptions from the day-to-day tasks, and
  2. Putting people is a different, pleasant surrounding may spark imagination, creativity and innovation.

2)      Prepare for the Environmental Scan – keep a running tab, file, post-it notes or what ever system you want to keep items that will be included into the environmental scan throughout the year prior to going into the planning session. We use several categories for the environmental scan such as economic, social-cultural, technological, political and legal, macro-industry, resources, market, competitors and suppliers. Whenever you come across a useful piece of information related to any of these categories read it and keep it for the planning session. You can’t possibly remember something interesting, fact or statistic from eleven months ago that could have a possible impact on your business next year. Create a system to keep this information readily available to you as you prepare for the Hoshin Kanri session.

3)      Have an experienced facilitator – this process will work better if you have person lead you through the process. Of course if makes sense to have someone (or more than one) person act as the time-keeper, scribe, coach, mentor, and referee. Use can use someone internal or bring in an external resource. The facilitator will make sure that all the appropriate items are ready onsite for the management team. This person’s number one goal should be to keep everyone on track, focused, and committed to bringing about the framework for your Hoshin plan.

So these were a few quick tips on getting ready for your Hoshin Kanri session. I’m sure I’ll have more coming soon in the blog – stay tuned. If we prepare correctly our Hoshin planning session will go much smoother and hopefully with better results.

Please share what’s worked for you in the past (or what hasn’t) when it comes to Hoshin Kanri or your strategic planning sessions.

 Thanks – Tony