Michael Ballé's Gemba Coach Column
Michael Ballé PhD, is a business writer and executive coach, who has studied and guided lean transformations for 20 years. He is Associate Researcher at Télécom ParisTech's Projet Lean Enterprise and the co-founder of the French Lean Institute-
How can I tell good lean consultants from bad?
June 19, 2017If lean’s not a scam – but there are scammers -- how can I distinguish good lean consultants from bad? read more »
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Follow-up to your comments on the “lean is a scam” column
June 5, 2017Thank you for reading and taking the time to comment. Maybe the original questioner’s use of “scam” was a bit of an exaggeration. read more »
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Isn’t lean just a scam to squeeze teams for more production?
May 22, 2017Lean is a scam. People like you who write about “respect” are pushing a smoke screen that allows consultants to just squeeze teams for more production without ever resolving the company’s deeper problems. read more »
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How can we tell if gemba walks by our CEO are actually improving the business?
May 14, 2017Dear Gemba Coach, We’re instituting a program of gemba walks by our CEO. How will we know if we’re progressing? read more »
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Shouldn't lean focus on solutions, rather than problems?
May 4, 2017Dear Gemba Coach, Why is lean so focused on problem solving? Isn’t seeing everything as a problem negative? Shouldn’t we focus on solutions instead? Wouldn’t that be more positive and more creative? read more »
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What’s your opinion on setting specific criteria before brainstorming countermeasures?
April 24, 2017I’m thinking of criteria that create a challenge, but stimulate a creative solution, e.g. cost (no money, or keep within budget) ... read more »
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Isn’t lean all about culture?
April 17, 2017Dear Gemba Coach, Isn’t lean all about culture, really? read more »
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What do you mean by developing people?
April 10, 2017Dear Gemba Coach, What do you mean by developing people? read more »
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What do you think are the pros and cons of merging lean and TOC?
March 30, 2017Dear Gemba Coach, In the DevOps movement, the amalgamation of agile, lean, and IT service management practices, there is a new entry that is making a big impact. This is The Theory of Constraints by [Eliyahu] Goldratt. Many believe that combining the thinking of Ohno and Goldratt can produce amazing and sustainable results far easier and faster than either can separately. Have you considered the pros and cons of lean and TOC or merging them? read more »
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How do we deal with a command-and-control boss?
March 27, 2017Dear Gemba Coach, Our boss always says, “It’s not my job to tell you how to do yours!” But then he tells us what to do all day long. How do we deal with this? read more »
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Is there a lean way of delegating?
March 3, 2017Dear Gemba Coach, I’m an entrepreneur and I used to micromanage everything, quite successfully. Now the firm has grown and I’m trying to delegate. How do I stop myself from cutting in when the actions my department heads want to take are plain silly, or not very creative? read more »
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We meet daily to examine a new customer complaint. What do we do next?
February 27, 2017Dear Gemba Coach, We’re a start-up and have taken your advice: we now have a customer wall and we meet daily to look into a new complaint. What do we do next? It’s hard to know what to do or how that helps? read more »
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What's the lean take on learning?
February 21, 2017Dear Gemba Coach,Our previous CEO used to preach “servant leadership,” but now’s he’s left and the new style is far more traditional command and control. I’m personally interested in learning leadership and wondered what the lean take on it would be? read more »
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Does lean change how you think about business?
February 13, 2017Dear Gemba Coach I can see that lean changes how one thinks about business, but can’t quite put my finger on it. If you had to sum up the main changes in thinking, what would they be? read more »
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Is "lean" now just an over-hyped word that is losing its value?
January 30, 2017I have spent the day with a group of people in the LeanIT, Agile, ITSM, IT4IT, DevOps, etc. worlds. We were all more or less saying the same thing; using the same words. In your opinion, is "lean" now just an over-hyped word losing its value? read more »
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Should value-stream mapping come before 5S?
January 19, 2017Dear Gemba Coach, Shouldn’t VSM come before 5S so we see the whole picture first? read more »
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Is promising that lean will make work more meaningful disrespectful to people?
January 16, 2017Dear Gemba Coach, Can lean really make work more meaningful for everybody? Isn’t this overpromising to workers and disrespectful to them because management really can't deliver on the promise? read more »
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What kind of conversation should I expect during a gemba walk?
January 9, 2017One important thing to keep in mind is much of the key parts of the gemba walk conversation happen before and after actually being on the gemba. read more »
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What are your three most important problems?
January 3, 2017What to look for during a gemba walk. read more »
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Does implementing lean mean creating a lean management system?
December 19, 2016Dear Gemba Coach, My understanding is that implementing lean means setting up a lean management system. You seem to disagree. Would you explain? read more »
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Why does my team resist multi-skilling?
December 12, 2016Dear Gemba Coach,I’m trying to introduce multi-skilling in my team but am surprised by the amount of resistance I encounter from my team members. What am I missing? read more »
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Do andons apply to software development?
December 6, 2016Dear Gemba Coach, I work in software development, and I really don’t see how andon applies – what am I missing? read more »
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Does a Lean Company Need Explicit or Implicit Leadership?
November 28, 2016Dear Gemba Coach, Explicit leadership or implicit leadership? Does an explicit style sustain a lean organization? read more »
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Does lean have an ethical perspective other than goal-oriented efficiency?
November 14, 2016Dear Gemba Coach, As a follow-up to your previous column on the question of whether lean has a spiritual dimension, does lean have an ethical perspective other than goal-oriented efficiency? read more »
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Is there a spiritual dimension to lean?
November 7, 2016Dear Gemba Coach, Is there a spiritual dimension to lean? read more »
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What's the difference between a sensei and a consultant?
October 31, 2016Dear Gemba Coach, Is there a difference between a sensei and a consultant? Beyond the way they market themselves, don’t they do the same thing? read more »
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What should I know about lean management that I won’t find in books?
October 21, 2016Dear Gemba Coach, I’m new to lean and reading all I can find about it, but is there something specific I need to look out for; is there something I should know that I won’t find in the books? read more »
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Our new boss doesn’t 'get' lean; what can I do to convince him?
October 6, 2016Dear Gemba Coach, We’ve had spectacular lean results with our old boss, but our new boss doesn’t get it. He’s already cut his gemba walks from weekly to monthly and doesn’t see the point of kanban. What can I do to convince him? read more »
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How can kanban or lean possibly apply in an office?
October 3, 2016Dear Gemba Coach, You often say that one can’t do lean without kanban, and that continuous improvement without kanban is fine, but not lean. My team works on projects in an office, I fail to see how kanban applies. Are we barred from lean forever? read more »
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What are the elements of knowledge-based product development?
September 26, 2016Dear Gemba Coach, What would be a knowledge-based approach to product development? read more »
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Does respect for humanity mean the same as respect for people?
August 30, 2016Dear Gemba coach,Does respect for humanity mean the same as respect for people? I hear that the literal translation of the Japanese phrase “respect for people” is really respect for “humanness” – whatever that means? read more »
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Guest Post: Insights on Daily Problem Solving
August 29, 2016Guest Post: Insights on Daily Problem Solving read more »
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Does a lean transformation boost a company's stock price?
August 22, 2016Dear Gemba Coach, You’ve worked with a lot of different companies in the public and private sectors. How have the stock prices of the public companies done? read more »
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What is leader standard work?
August 15, 2016Dear Gemba Coach, Is there such thing as a leader standard work, and, if so, what is it? read more »
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Do we need more research to understand what works and what doesn’t when implementing lean healthcare?
August 1, 2016Dear Gemba Coach, There are controversies over whether lean/TPS works in healthcare or not. Authorities in lean practice suggest conducting research that compares outcomes with lean and without. I feel like we are stuck proving wasteful activities are still valid when we run to research. read more »
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How do we pass the baton from one lean leader to the next?
July 25, 2016Dear Gemba Coach, What are your thoughts about ensuring that a lean transformation persists past a leader’s tenure at an organization? read more »
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We’re installing an andon system – what should we expect?
July 18, 2016Dear Gemba Coach, We’re installing an andon system – what should we expect? read more »
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What does “daily problem solving” really look like in practice?
July 11, 2016Dear Gemba Coach,I hear the phrase “daily problem solving” a lot. But what does it really mean in practice and how does it work? read more »
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Why does kaizen feel like chaos?
June 27, 2016Dear Gemba Coach, Why does kaizen always feel so destabilizing? read more »
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How can I keep our lean management effort from becoming bureaucratic?
June 14, 2016Dear Gemba Coach, Isn’t there a risk that all these lean tools in the workplace turn into yet more bureaucracy read more »
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How important is it to consider differences in roles between our current project manager and a chief engineer?
June 6, 2016Management wants us to start lean in product development, but refuses to consider the difference in roles between our current project manager and a chief engineer – how important is that? read more »
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I’m struggling to understand exactly what people mean by a “lean system”?
May 30, 2016I’m struggling to understand exactly what people mean by a “lean system”? read more »
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How do I implement standard work in an office environment?
May 23, 2016Dear Gemba Coach, I really enjoyed reading your article on the difference between standard work and procedures back in December. It really helped clarify the differences. However, I still struggle with the idea of standard work in an administrative area. Can you explain further how to implement in an office environment? read more »
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Our technical guys are really resisting the idea of standard work. What should we do?
May 16, 2016Dear Gemba Coach, Our technical guys are really resisting the idea of standard work. They believe they each have their own way of working and don’t want to share. What should we do? read more »
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Any step forward in a lean transformation is a good step -- right?
May 2, 2016Surely a step forward in a lean transformation is a good thing, even if it’s not completely in the right direction? read more »
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What do you think about a new boss who wants us to use A3s to solve problems rigorously?
April 25, 2016Dear Gemba Coach, My new boss wants us to use A3s to “teach us how to solve problems rigorously” – her words. I find the process cumbersome, it goes against everything I know about creative problem solving and, personally, I resent the idea that my boss wants to teach me how to think. What’s your take on this? read more »
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Why won't operators use andons?
April 18, 2016Dear Gemba Coach, We’re struggling with andons. We’ve set up a button for operators to press and call for help, but they’re not using it as much as we hoped, and we don’t know how to make it work properly. Any thoughts? read more »
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Rather than narrow problem solving, shouldn't we look for disruptive breakthroughs?
April 11, 2016Dear Gemba Coach, How can a narrow focus on problem solving help us to find innovative solutions? Shouldn’t we be looking for disruptive breakthrough instead? read more »
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What are the pitfalls of implementing hoshin kanri?
March 28, 2016Dear Gemba Coach, I’ve heard of hoshin kanri, and I’d really like to try it in my company – what should I keep in mind? read more »
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How do I introduce kaizen to IT?
March 14, 2016Dear Gemba Coach, Based on your experience, what is the best strategy to introduce kaizen as social, ongoing events without start and end dates in a service industry, specifically IT services? read more »
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How is lean different from Taylorism?
March 7, 2016In a special column, Michael Ballé breaks from his standard practice of answering readers’ questions to weigh in on the controversy comparing lean management to “Taylorism” triggered by the recent story “Medical Taylorism” in the New England Of Medicine. read more »
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Does lean apply to sales?
February 27, 2016Dear Gemba Coach, Does lean apply to sales? We’re trying to introduce lean thinking throughout the company and have found very little on how to lean the sales department. read more »
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What does “separating human work from machine work" mean?
February 15, 2016Dear Gemba Coach, What does “separating human work from machine work mean?” How does it matter? read more »
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What is the best way to start gemba walks and keep them focused ?
February 15, 2016Dear Gemba Coach, We are looking to implement gemba walks in our facility. This is new to everyone including myself although I have been exposed to them in the past. What is the best way to get started and keep them focused? How do you trainor teach people what to look for? read more »
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What is your opinion about transformation process steps?
February 8, 2016What is your opinion about transformation process steps? First we choose a problem and start problem-solving processes (A3 or 8-step methods) and after the steps create our first standards; OR first write down the processes as they are now and choose problems to solve by measuring the gaps between first standards and our goals? read more »
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How do I convince management to run to takt time, not as fast as possible?
January 31, 2016Dear Gemba Coach I have always struggled with convincing management about the importance of running to takt time, since the mindset is typically run as fast as possible. How would you address this issue with management? read more »
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How does continuous flow apply to healthcare or other service industries?
January 25, 2016Dear Gemba Coach, I work in healthcare and I struggle with how the concept of flow, which I can well understand in production, applies in service? read more »
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How do I quantify kaizen's small improvements?
January 18, 2016Dear Gemba Coach, How do I quantify kaizen's small improvements? read more »
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What is the difference between standard work and procedures?
December 28, 2015Dear Gemba Coach, What is the difference between standard work and procedures? read more »
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How do you introduce visual management into a product development facility?
December 21, 2015Dear Gemba Coach, What steps do you start with to introduce visual management into a product development facility? read more »
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What is the lean approach to quality – is that what six sigma is all about?
December 7, 2015Dear Gemba Coach,I’m a frequent reader of your columns and you always seem to emphasize quality first, but I can’t find many books detailing a lean approach to quality – is this what six sigma is about? read more »
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How can I speed up my team’s lean learning?
November 30, 2015Dear Gemba Coach,How can I speed up my team’s lean learning? read more »
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Why you can't convince your boss to support lean activities, unless ...
November 16, 2015Dear Gemba Coach,I work as a deployment champion in a manufacturing company, but I don’t have the support of my managers because they don´t believe in the lean methodology. Which lean tools can be used to help them believe? read more »
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Why are there so many different opinions about what lean management is and isn't?
November 2, 2015Dear Gemba Coach I have attended several lean conferences and am deeply interested in the topic, but puzzled about the diversity of viewpoints. Any advice on how to make up my own mind about what “lean” really is? read more »
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How do I reconcile the lean healthcare goal to organize around the patient with management demands to cut costs?
October 13, 2015Dear Gemba Coach, I’m the lean director at a hospital where the board keeps investing and then asking us to cut costs. I understand lean aims for better patient care and reduced lead times, but I’m having trouble reconciling this with my CEO’s demands. Any advice? read more »
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How and Where Should I Start Using Andons?
October 5, 2015Dear Gemba Coach, I understand the andon is an essential part of a lean system, but it seems very far from our work culture and I do not know where to start. Any advice? read more »
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Is your obeya room used for real learning or as a glorified action plan?
September 28, 2015Dear Gemba Coach, How can I use an obeya for learning rather than for project management? read more »
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Is there a way to define standard work for senseis?
September 21, 2015Dear Gemba Coach,I’ve been working on lean projects for years and my CEO has now asked me to act as the lean sensei for our company. Is there a way to define standard work for senseis? read more »
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Gemba, workplace, genchi genbutsu, go-and-see ... What’s the difference?
September 14, 2015Dear Gemba Coach, Is there a difference between “gemba” as used in lean texts and “genchi genbutsu” as they appear in Toyota literature? read more »
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Is a lean CEO's job different from a traditional CEO?
August 31, 2015Dear Gemba Coach, How does the role of CEO in lean management differ from that in traditional management? read more »
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Does being “sensei-ed” show respect for people?
August 17, 2015Dear Gemba Coach,If lean is based on respect for people, why are sensei gemba visits reputed to be so tough? read more »
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What the heck is a dojo?
July 27, 2015Dear Gemba Coach, What is a “dojo”? I hear about it but don’t find it referenced in the lean tools. Is it important? read more »
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Am I doing lean right? How can I tell?
July 20, 2015Dear Gemba Coach,I’m spending a lot of time at the gemba, but how do I know if I’m doing good lean? read more »
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My CEO, who supported lean, has left and been replaced by a pure finance guy. It doesn't look good for the lean effort. What should I do?
July 13, 2015Dear Gemba Coach,My CEO, who supported lean, has left and been replaced by a pure finance guy. It doesn’t look good for the lean effort. What should I do? read more »
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How can I tell if people “get” lean thinking; what signs should I look for?
June 29, 2015Dear Gemba Coach, I’ve been training teams to do lean, intensively at first, and with paced-out coaching later. How do I know if they “get it”? What should I be looking for in behavior change? At what point should they be autonomous? read more »
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Two managers I relied on a lot are still fighting a two-year-old pull system and creating a lot of conflict on the team. Is this normal?
June 18, 2015I’m two years into establishing a pull system through my plant. It hasn’t been easy because of the high mix/low volume environment, but I feel we’re getting there with clear improvements in service and lower inventories. However, two of my key managers are still fighting the system and creating a lot of conflict on the team. These are good guys I used to rely on a lot, but now I don’t know. Is this normal? read more »
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Could hoshin kanri be too bureaucratic for my small tech company?
June 9, 2015I started a new IT services company 15 years ago and we’ve grown to 20 people. We must keep abreast of new tech, but I get frustrated with being the only one seriously concerned with experimenting and learning new systems, so I implemented hoshin kanri to get others on board. I'm getting a lot of pushback that hoshin is too bureaucratic for our size. Is this normal resistance? Should I stick with it, or regroup and rethink? read more »
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My management team feels tense and pressured about going to the gemba. Is this normal?
May 28, 2015Dear Gemba Coach, I’ve decided to take my management team to the gemba to get them to solve real problems but this is creating a lot of tension and they complain of the pressure. Is that to be expected? read more »
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I've had visible results with lean but my corporate colleagues want to force their ERP and purchasing practices on my division. Any advice?
May 11, 2015Dear Gemba Coach, I’m the head of a business unit and have had visible results with lean. Yet, my corporate colleagues refuse to acknowledge this and want to force their ERP and purchasing practices on my division. This is very frustrating – any advice? read more »
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How is leadership engaged and trained in lean?
May 4, 2015Dear Gemba Coach, How is leadership engaged and trained in lean? read more »
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How do you protect jobs while reducing lines and shifts?
April 20, 2015Dear Gemba Coach,How do you protect jobs while reducing lines and shifts? read more »
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How Do I Measure People Development?
April 6, 2015Dear Gemba Coach, What is the metric for people development? read more »
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Why do we hear less and less about lean in manufacturing?
March 30, 2015Dear Gemba Coach,Why do we hear less and less about lean in manufacturing? Is it that most companies have implemented lean successfully or at least elements of lean? read more »
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What does customer focus really mean?
March 16, 2015Dear Gemba Coach, We’re discussing improving our customer focus, but we’ve realized we’re not quite sure what the phrase really means. Any pointers? read more »
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How demanding can a lean leader be while remaining respectful of staff?
March 9, 2015Dear Gemba Coach,How demanding can a lean leader be while remaining respectful of staff? read more »
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Dear Gemba Coach,
Is there a difference between executive coaching and lean coaching?
February 23, 2015Dear Gemba Coach,Is there a difference between executive coaching and lean coaching? read more »
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After improving processes with help from a consultant, how do I sustain kaizen in my department? My teams are hard to motivate.
February 17, 2015Dear Gemba Coach,How do I sustain kaizen in my department? We’ve had a consultant help us with workshops, and we did improve our processes, but I struggle with moving to continuous improvement, as my teams are hard to motivate on this. read more »
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How can I estimate the savings from using visual management boards?
February 9, 2015Dear Gemba Coach,I work on a lean team and I was asked to estimate the savings from using visual management boards. The current estimate is that we save about 5% of people’s time as a result of realigning resources and driving performance. Would you know of any studies in this area? read more »
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How Do You Spread a Lean Transformation from One Site to Many?
February 2, 2015My CEO has asked me to spread lean to 30 other sites. How should I go about it? read more »
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In IT, can we do virtual gemba walks?
January 27, 2015Dear Gemba Coach, I am part of an IT creation and support organisation. How do you do a gemba walk, initially or afterwards, when management and the business customer are in one country, IT development in another, and IT OPS is in another? read more »
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Dear Gemba Coach,
Is there a lean strategy?
January 18, 2015Dear Gemba Coach,My team demonstrated the benefits of kaizen to the CEO who then asked us what our strategy was. Is there a lean strategy? read more »
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How do I set up an obeya room?
January 12, 2015Dear Gemba Coach,I’d like to set up an obeya room – where should I start? What’s the simplest way to do it? read more »
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Any tips for conducting daily stand-up meetings with my team?
January 5, 2015Dear Gemba Coach,I’ve been told I should conduct daily stand-up meetings with my team to solve problems collaboratively. I’m not sure how to do it — any tips? read more »
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I’m not sure I understand solving problems one by one.
December 19, 2014Dear Gemba Coach,I’m not sure I understand solving problems one by one. I thought listing problems and pushing hard to get them solved faster would improve my operations faster – am I missing something? read more »
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How Do Lean Concepts Apply in an Office Environment?
December 15, 2014Dear Gemba Coach,How does lean apply in an office environment? I’m excited by the ideas but can’t figure out learning to see when there’s nothing to see. read more »
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Is lean just another word for productivity?
December 8, 2014Dear Gemba Coach Isn’t lean about productivity before all else? read more »
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Is momentum loss normal during a lean transformation?
November 25, 2014Dear Gemba Coach, One of our outpatient wards reduced waiting time by 75% and got an award for their lean improvement project. But then momentum was lost and waiting time is now worse than it ever was. Is this loss of momentum normal? read more »
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How do we solicit feedback from the shop floor without being overwhelmed by the enormous amount of ideas?
November 19, 2014Dear Gemba Coach,My company is trying to implement a system for collecting, organizing, and maintaining visibility of employee suggestions and ideas. I think we all know that the "suggestion box" has gone by the wayside. How do we solicit feedback from the shop floor without being overwhelmed by the enormous amount of amazing ideas that we're asking for? read more »
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Can creative people, like product developers, follow such a structured method such as lean?
November 7, 2014Dear Gemba Coach,For product development you need creative (maybe even chaotic) people. Are those people suited to follow such a structured method as lean? Like trying to achieve one-piece-flow in product development? read more »
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What do you actually do on the gemba?
November 4, 2014Dear Gemba Coach, What is it you actually do on the gemba? read more »
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My boss has asked me to take on the sensei role for the company. What does that mean?
October 28, 2014Dear Gemba Coach,How do I become a sensei? My boss has asked me to act in the sensei role for the company but I’m not sure what that means – any advice? read more »
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How is standardized work different from the Taylorist one best way?
October 19, 2014How is standardized work different from the Taylorist one best way? read more »
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How can I train technical experts who know more about the work than I do?
October 6, 2014Dear Gemba Coach,I understand I have to train people, but I work in a very technical area and they all know far more about their jobs than I ever will. How can I train them if they know more than I do? read more »
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I’m a six sigma black belt and have now been ask to do lean. I’m not sure where to start with my team. Any advice?
September 29, 2014Dear Gemba Coach,I’m a six sigma black belt and have now been ask to do lean. I’m reading the literature and there’s a lot to absorb. I’m not sure where to start with my team. Any advice? read more »
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How should I accelerate my own learning?
September 22, 2014Dear Gemba Coach,How should I accelerate my own learning? read more »
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Would you have a fresh perspective on 5S to make it more motivating?
September 10, 2014Dear Gemba Coach,I’m the manager of a plant that has changed hands (again). The new corporate team finds my 5S insufficient (again) and want me to make a 5S drive (again). Would you have a fresh perspective on 5S to make it more motivating? read more »
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I fail to see the difference between hoshin kanri and the strategic planning we used to do. What am I missing?
August 18, 2014My boss has hired a consultant to take us through the Hoshin Kanri process. So far, I fail to see the difference with the strategic planning we used to do. What am I missing? read more »
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What does developing people mean?
August 7, 2014Dear Gemba Coach,Are people tools? Should bosses use people? What does development mean? How should we think about it? read more »
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What's new in your new novel "Lead With Respect"?
July 29, 2014Dear Gemba Coach,I see that you have a new lean management novel out called Lead With Respect. What's new in it? read more »
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What? My Pull System Is Supposed to Fail?
July 11, 2014Dear Gemba Coach,We’ve given up on installing a pull system – every time we try, our on time delivery rate plummets, and we can’t let customer service suffer more than it already does. We’re doing a lot of A3 problem solving – isn’t that lean enough? read more »
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Am I doing PDCA correctly?
June 30, 2014Dear Gemba Coach,How do I know if I’m doing PDCA correctly? read more »
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We found your visit rather challenging ... does “real” lean have to be such a struggle?
June 12, 2014I’ve just finished your two novels after your visit to our plant. I have to say we found your visit rather challenging, which I can now put in better context after reading the books and look forward to your next one. The question I’m facing internally however is whether “real” lean needs to be that challenging or is there an easier way to do lean projects without questioning as much what has been done in the past? read more »
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Are computer screens okay for visual management?
June 4, 2014Dear Gemba Coach,Can I use computer screens for visual management or is that a big no-no? read more »
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Could you clarify the difference between cause and root cause?
May 29, 2014Dear Gemba Coach,Could you clarify the difference between cause and root cause? read more »
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What's the main quality I should look out for in hiring a lean coach?
May 14, 2014Dear Gemba Coach, I’m in the process of hiring a Lean Coach for my team and I wondered if there was any one quality I should look out for? read more »
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I want to apply lean to engineering. Any thoughts?
May 4, 2014Dear Gemba Coach I am the regional manufacturing VP of a large industrial company. After the latest reorganization, engineering now comes under me. I’ve had good success with lean in manufacturing and want to apply it to engineering. I plan to get engineers to solve production problems faster. Any thoughts? read more »
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Why do you lean guys always focus on shop floor processes? The lack of clarity and focus at headquarters is far worse! As a plant manager, I feel I’ve solved most of the issues our lean coach keeps badgering me about, why don’t they go and kaizen head office instead?
April 21, 2014Why do you lean guys always focus on shop floor processes? The lack of clarity and focus at headquarters is far worse! read more »
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What is the worst mistake you’ve made on the gemba?
April 10, 2014Dear Gemba Coach,What is the worst mistake you’ve made on the gemba? read more »
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We’re being audited on five levels on fifteen topics. I feel that if we actually worked on all these items, the plant would just stop working. Am I missing anything?
March 27, 2014Dear Gemba Coach,Our facility is being rated on a “lean maturity” audit. We’re being audited on five levels on fifteen topics, each having multiple sub-topics. I feel that if we actually worked on all these items, the plant would just stop working. Am I missing anything? read more »
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Why do the characters in your books struggle a lot with lean?
March 18, 2014Dear Gemba Coach,I’m new to lean and I’ve just finished reading The Gold Mine and The Lean Manager and enjoyed them thoroughly – thank you. I do have a question: the characters seem to struggle a lot, and there’s a lot of conflict. Is that always the case or is it in there to make the books more interesting? read more »
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I’ve heard you say the quality department is the worst enemy of quality. I find this offensive.
March 3, 2014Dear Gemba Coach,I’m in the quality department of a large company and I’ve heard you say quality is the worst enemy of quality. I find this offensive, but I’m willing to keep an open mind. How would you back up such an outrageous statement? read more »
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If I turn off MRP in favor of kanban, will the factory collapse around us?
February 24, 2014Our sensei wants us to turn off MRP and work with kanban cards. I’m really nervous about this. We’ve been doing a lot of problem solving, but I’m not sure we’re ready. Any insights? read more »
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I don’t find much about lean strategy in the literature. Where should I look?
February 10, 2014Dear Gemba Coach,I’ve been tasked to come up with a presentation on what is a “lean” strategy to our Strategic Planning Group. I don’t find much about lean strategy in the literature and am stumped. Where should I look? read more »
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In TPM, Isn't it needlessly costly to replace parts that are working fine? What do you think?
January 28, 2014Dear Gemba Coach, I have a question about Total Productive Maintenance. My management has hired a TPM consultant who makes us systematically replace certain parts in our equipment even though they’re working fine. This seems needlessly costly. What do you think? read more »
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Why do you lean experts still revere the Toyota Production System? Hasn't any one come up with something better?
January 22, 2014Dear Gemba Coach,Since Toyota formulated TPS 50 years ago, many other companies have come up with their own business systems – I have been taught the Nissan Production Way. Why do you lean experts still revere the Toyota Production System? Hasn't any one come up with something better? Is this just conservatism or ideology or do you actually have a reason to stick with TPS? read more »
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We struggle to set target conditions. Is there a system to do so?
January 14, 2014Dear Gemba Coach,We work with Toyota Kata, which we find very helpful, but we struggle to set target conditions. Is there a system to do so? read more »
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How does lean fit together with Lean Startup concepts?
January 6, 2014Dear Gemba Coach,I work in IT and discovered lean through the Lean Startup movement. Now, as I read more about it, I find that lean is about the complete elimination of waste. How does that fit together with Lean Startup concepts? read more »
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What Exactly Is - or Isn't - a Lean System?
December 20, 2013Dear Gemba Coach,I’m confused as to what a “lean system” is or should be. Could you clarify? read more »
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Is there such a thing as lean manufacturing engineering?
December 4, 2013Dear Gemba Coach,I keep reading about lean engineering and lean design. Is there lean manufacturing engineering? read more »
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My CEO would like to install a lean culture and has asked me to specify a few basic lean values we need to implement. Where should I start?
November 21, 2013Dear Gemba Coach,My CEO would like to install a lean culture in our company and has asked me to specify a few basic lean values we need to implement. Where should I start? read more »
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How do I re-size supermarkets when demand changes or to keep pace with seasonality?
October 28, 2013Dear Gemba Coach,How do I calculate re-sizing supermarkets when demand changes or to keep pace with seasonality? read more »
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Fighting fires vs. problem solving: what's the difference?
October 20, 2013Dear Gemba Coach, I hear that lean is about less fighting fires and more problem solving but I am unsure of how one differs from the other? read more »
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Product and Process Lean
October 8, 2013Dear Gemba Coach,Lean product development guys tout the gospel of product focus as core to lean success. No argument from me. But ... how, if the customers are famously wrong about what they really want, do we focus on the product and still give them what they really need? It feels like we're running on two different tracks. read more »
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Why is it still so hard to convince executives to adopt the lean spirit?
September 13, 2013Dear Gemba Coach,Why, in your experience, after all these years of preaching lean, is it still so hard to convince executives to adopt the lean spirit? read more »
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Can a pull system with zero stock make the company more fragile?
September 10, 2013Dear Gemba Coach,Can a pull system with zero stock make the company more fragile? read more »
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How do you define respect for people?
August 27, 2013Dear Gemba Coach,Can you be more specific about “respect” in lean? The term is being used in our company but I fear it sounds just like “motivation,” “every one has to be a leader” and the rest of management speak. read more »
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Why reduce inventory further?
August 7, 2013Dear Gemba Coach,We have a lot of machining operations in our process, and we carry inventory. What is the best way to show employees the value of reducing inventory—and how this relates to the need for continuous improvement? Our employees believe that some level of inventory is necessary to keep parts flowing, and that they’re already good at what they do, so there is no need to aim for better. read more »
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Should I use an A3 report to kick off a problem-solving effort?
August 1, 2013Dear Gemba Coach,Should I use an A3 report to kick off a problem? I encourage my managers to tell me about their problems on the shop floor. They always pull something out of the air and say ‘lets work on this...’ What I would really like is for them to create some kind of A3 report that explains why this problem is happening. Any advice? read more »
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Does quality really come first?
July 22, 2013Dear Gemba Coach,I’ve been practicing lean for many years and have learned to create flow and one-piece-flow. However I still struggle with quality problems. I hear that quality comes first, but face many challenges trying to put this phrase into practice. What’s your take on this? read more »
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Can lean go wrong?
July 15, 2013Dear Gemba Coach,Can lean go wrong? Can the ideas be misused and can the outcome be bad for the company? Is there any way to prevent this? read more »
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Why aren’t the laws of lean articulated?
June 19, 2013Dear Gemba Coach,Aren’t there laws of lean, just as there are laws of physics? And why aren’t these clearly articulated yet? read more »
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Why don’t middle managers practice A3 thinking? (Part 2)
June 3, 2013Dear Gemba Coach,I’m a lean consultant, and have been hired by a large service organization to develop an A3 problem solving training program for their middle-management. Why is it so hard to engage middle-managers in rigorous analysis? It’s not that they don’t understand the concepts or that they don’t feel it could help. They often just don’t seem to get it. How can I do my work here? read more »
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Why don’t middle managers practice A3 thinking?
May 28, 2013Dear Gemba Coach,I’m a lean consultant, and have been hired by a large service organization to develop an A3 problem solving training program for their middle-management. Why is it so hard to engage middle-managers in rigorous analysis? It’s not that they don’t understand the concepts or that they don’t feel it could help. They often just don’t seem to get it. How can I do my work here? read more »
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Why Are There So Many Points of View About What Lean Is?
May 4, 2013Dear Gemba Coach,I’ve been interested in lean for over two years now, and can’t quite understand why after 20 years there are still so many points of view, and no apparent single message under the lean banner. What are your views on this? read more »
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Why Does Our Recognition Program Just Feel So Bad?
April 25, 2013Dear Gemba Coach, My company has put an employee of the month program and other related efforts to reward good behavior. So why does it feel so bad? read more »
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Operator morale has suffered terribly since we implemented cell manufacturing, and the ideas that kaizens generate have been weak. Would you please share your insights on this situation?
April 18, 2013Dear Gemba Coach,Operator morale has suffered terribly since we implemented cell manufacturing, and the ideas that kaizens generate have been weak. Would you please share your insights on this situation? read more »
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Part2: What is the best lean way to understand VALUE (in terms of what our customers want)?
April 2, 2013Dear Gemba Coach, What is the best lean way to understand VALUE (in terms of what our customers want) read more »
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Part 1: What is the best lean way to understand VALUE (in terms of what our customers want)?
March 26, 2013Dear Gemba Coach, What is the best lean way to understand VALUE (in terms of what our customers want)? read more »
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How do we get started with lean tools in new product development?
March 8, 2013Dear Gemba Coach,My company already has a deep rooted lean culture. However, it would seem that the next evolution would be in my department, Research & Development. Do you have any suggestions on how to take lean tools from process improvements such as kaizen, 5S, etc. to new product development? read more »
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How do we get started with standard work?
February 27, 2013How do we get started with standard work? The literature seems to say there can’t be meaningful kaizen without standards, but although we have procedures for everything, they seem very far removed from “standards.” I think I see what we need to do but the job seems daunting! read more »
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Why haven't kanban and value-stream mapping improved delivery from a low-volume/ high-mix process?
February 21, 2013Dear Gemba Coach,We work in a low-volume/ high-mix process with component machining and assembly. Our OTD is somewhere between 70% and 80%. We’ve invested heavily in value-stream mapping and kanban, but can’t seem to improve our delivery. Any advice? read more »
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My CEO has asked me to take a hard look at the lean program at our hospital – where should I start?
February 11, 2013Dear Gemba Coach,I am ops director of a large hospital. We have been doing lean for several years now, with a lean office of 10 people involved in many projects improving 5S, finding beds, test circuits, and so on, but lean doesn’t seem to “take,” and our financial situation is not improving. My CEO has asked me to take a hard look at the lean program – where should I start? read more »
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Would you have a few tips about coaching on the gemba?
January 28, 2013Dear Gemba Coach,Would you have a few tips about coaching on the gemba? read more »
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How is lean strategic?
January 21, 2013Dear Gemba Coach,I’ve been told by my senior management that there is no strategic vision in lean and they don’t see how to integrate the lean initiative to the strategic plan. I’ve not found any reference to lean and strategy in the literature. Any advice? read more »
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Why won’t senseis ever give a straight answer?
January 13, 2013How many lean senseis does it take to change a light bulb? One, the joke goes, but the light bulb has to really want to change. read more »
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Why audit standard work? And what is the best approach?
January 1, 2013Dear Gemba Coach,Can you help me determine the best way to conduct audits of standard work (SW)? The Toyota Way Fieldbook describes a layered SW auditing system. Team Leaders audit their five-member team once per hour (40 audits/shift). A group leader may audit one of these teams once per hour (8 audits/shift). The frequencies follow suit as you go up the organizational hierarchy. What auditing frequency have you seen to be most effective? read more »
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Why isn’t there more emphasis on lean engineering?
December 17, 2012Dear Gemba Coach, Why isn’t there more emphasis on lean engineering? read more »
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How do I convince senior management to visit the shop floor?
November 30, 2012Dear Gemba Coach,How do I convince my senior management to get interested in our kaizen projects? In fact, how can I simply convince them to visit the shop floor? read more »
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How can we reconcile the lean principle of respect for people with our disrespectful atmosphere?
November 26, 2012Dear Gemba CoachMy company's lean program stigmatizes competent people as “concrete heads” for disagreeing with the lean coaches, even when the coaches' prescriptions make no business sense. What used to be a good work atmosphere is now poisoned by resentment and distrust. How can that be compatible with the “respect for people” message that you say is so central to lean? read more »
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How do we mid-level managers convince the CEO and senior management that adopting lean practices is worthwhile?
November 2, 2012Dear Gemba Coach, The recent webinar on the business case for lean was particularly useful for us because it raised many questions and provided a lot of common sense insight. I'm an administrator taking lean certification training at a primary care network. How do we as mid-level "operators" convince our CEO and senior management that adopting lean practices and thinking are worthwhile? read more »
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What would a lean transformation mean for the IT Department? What benefits would it create for the company?
October 28, 2012Dear Gemba CoachWe’ve asked our IT department to be involved in kaizen events several times, but it is always very slow to deliver on what is asked. What would a lean transformation mean for this department? What benefits would it create for the company? read more »
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Do lean-minded finance professionals make a difference in appraising lean initiatives?
October 19, 2012Dear Gemba Coach, Good webinar, thank you. I would like to ask lean-minded fellow finance professionals if they make a difference in appraising lean initiatives from other investments in their companies, e.g. different project and investment appraisal techniques, hurdle rates, etc.? read more »
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Why do we need to discuss making the business case for lean?
September 28, 2012Dear Gemba Coach,I saw the invitation to your October 10 webinar on Making the Business Case for Lean. I wonder why we even need such a discussion. Isn’t making the business case a fundamental competency for any manager or executive leading a lean transformation? Why do you even need to discuss it? read more »
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How Do the Problems of Continuous Improvement Professionals Differ from Those of Line Managers
September 7, 2012Dear Gemba Coach,How do the lean-related problems or responsibilities of ci professionals differ from those of line managers or business unit managers?That is a profound question that links back to one of the fundamental differences between lean and traditional management. The difficulty here is… read more »
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How Should We Relate Lean Projects to KPIs in a Large Company?
July 26, 2012We have started a continuous improvement process with dedicated lean experts at each site. Until now our focus was on training. We link projects to a site impact-priority matrix. Management wants the improvements projects to be linked to key performance indicators (KPIs) such as on-time delivery and cost of quality. They want these KPIs identified, and progress reported on how the projects impactthe KPIs monthly. Could you guide me on how this can be done? read more »
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Are Lean Managers Teaching Or Just Controlling?
July 18, 2012Dear Gemba Coach,I hear what you lean guys are saying about, learning, “kata” and the role of managers as teachers. But in my years at Toyota I was never taught much. I learned a lot, but what my manager would mostly do is check the details of what I did and ask a lot of questions. I felt that it was very controlling. read more »
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Can Lean Boost Sales?
July 11, 2012Dear Gemba Coach,Every one says that lean is not just about cost cutting. But I fail to see how lean techniques can influence the top line. How can lean help in this area? read more »
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How Can Our Back Office Sustain Lean?
July 3, 2012Dear Gemba Coach,The improvement program at the back office of the bank where I am a lean facilitator is slipping. For t several years, we have improved operations by visualizing daily performance, conducting daily briefs, and teaching team leaders to solve problems. We have progressed visibly in quality and productivity. But our progress is harder to sustain. Teams that were doing great slip back and we must constantly regain lost ground. Is there a way to make lean more sustainable? read more »
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Can you help us define the role of team leader?
June 19, 2012Dear Gemba CoachMy lean team is creating a team leader role, and we are struggling to define this function accurately, not to mention that we are having trouble finding our places. Any advice? read more »
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Kaizen and Innovation
June 12, 2012Dear Gemba Coach,Can kaizen stifle breakthrough innovation? read more »
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Real lean vs. fake lean
June 6, 2012Dear Gemba Coach,I am a lean consultant who is totally dedicated to applying the lean principles. Unfortunately most lean gurus who I encounter seem to look down on our work. They argue that consultants like me don’t do “real” lean. Where do you weigh in on this? Are they being too snobby? Should I work to be more authentic in my practice? read more »
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How do you suggest we should do lean in a foundry?
May 22, 2012Dear Gemba Coach, How do you suggest we should do lean in a foundry? read more »
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It seems that lean these days is all about learning and coaching. What about the good ol'-fashioned just-in-time stuff of the earlier days?
May 2, 2012Dear Gemba Coach,It seems that lean these days is all about learning and coaching. What about the good ol'-fashioned just-in-time stuff of the earlier days? read more »
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What's the difference between model lines and kaizen events?
April 26, 2012Dear Gemba CoachWe used to do six sigma and are new to lean. Some consultants talk to us about model lines and others about kaizen events. Can you clarify the difference? read more »
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Management has a bad case of investment loss aversion. What can I do?
April 18, 2012Dear Gemba CoachI’ve been asked to take over the corporate lean program but the company’s investment plan favors large high-speed equipment, which I’ve come to see as one of our biggest roadblocks to leaner processes. But I’ve been told in no uncertain terms by senior management that I can’t denigrate past investment commitments or cast doubts on those which are currently planned. How do I respond to my superiors? read more »
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Should I Use Lean for Headcount Reduction?
April 10, 2012Dear Gemba Coach,My company wants to reduce its fixed costs. And as part of this my management has asked me to apply the lean techniques we’ve implemented in production to reduce headcount in engineering. I’m uneasy about doing this and wondered where I can find out more about lean in engineering departments. read more »
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How Do I Address Resistance From Middle Management?
March 27, 2012Dear Gemba Coach,Why does middle management resist lean transformations; how can they be brought on board? read more »
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How Do I Reduce Buffers To Zero?
March 20, 2012Dear Gemba CoachI run an assembly line for service station equipment. Our product is customized for each customer so we have a huge variety of options. My line is organized in segments (hydraulic assembly, wiring, etc.) with a buffer between each section of the line. I’ve long tried to reduce these buffers but haven’t found any good way to do it. Our lean consultant wants me to reduce the buffers to zero so that we have true one piece flow – should I do it? read more »
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Why Is It So Hard To Sustain Lean Gains?
March 13, 2012Dear Gemba Coach,Why is it so hard to sustain lean gains? read more »
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Can Hospitals Reap the Deeper Benefits of Lean?
February 29, 2012Dear Gemba CoachAs Health Systems globally wrestle with skyrocketing healthcare costs, many hospitals are jumping on the lean bandwagon, hoping this will be the silver bullet that delivers improved outcomes at lower cost. Is this a valid justification for implementing lean in hospitals, or is the cost-saving rationale as a driver of the process doomed to failure? read more »
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Lean and Forecasting
February 22, 2012Dear Gemba Coach,I’m in charge of the forecasting department in my company. My colleagues in production have been doing lean for several years and complain about my forecasts, particularly when it comes to what they call leveling. I have come across your column on lean.org and wondered if you could help out with some advice on how to forecast in a lean way? read more »
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How should I assess the success of our lean progress?
February 14, 2012Dear Gemba Coach,My management is asking for an assessment of our lean progress. How should I do this? read more »
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Five Whys
February 7, 2012Dear Gemba Coach,I’m a lean coach and teach A3s in my company. Every lean book mentions “5 why,” and I can see the power of it in theory but I struggle with it in practice. Any tips? read more »
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Gemba and Quality
February 1, 2012Dear Gemba Coach,We’ve made good progress on quality with Six Sigma, but we’ve reached a plateau. I’ve met a lean consultant who tells me I should spend more time on the shop floor, but I fail to see how it would improve quality? read more »
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Which is best for a lean environment, a U-shaped cell or assembly line? Why?
January 25, 2012Dear Gemba CoachWhich is best for a lean environment, a U-shaped cell or assembly line? Why? read more »
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Should we plan according to what we can do, or the other way around?
January 18, 2012Dear Gemba Coach,Should we plan according to what we can do, or the other way around? read more »
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How Do I Plan for the Long Term?
January 11, 2012Dear Gemba Coach,I don’t know how to plan for two or five years out. As a plant manager, my requirement is to be able to look at the next 12 months. And to do this I rely on guidance from a familiarity with lean policy deployment. Yet I worry that my skills in leadership are lacking because I don’t have a clear sense of how to conduct this long-term planning. How do I look ahead for the long term? read more »
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How Do We Sustain A3 Thinking in our Organization?
December 12, 2011Dear Gemba CoachMy firm has been investing a lot of time and energy this year in teaching A3 thinking to our staff. The workshops have been going great, but how do we keep this work going when people return to their daily work? How can we “pull” A3 thinking through the organization after the formal training is over? read more »
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Is There a Right Way to Teach A3?
November 8, 2011We’ve been teaching A3 problem solving to all our managers, but so far I fail to see any clear improvement of our problem solving ability. Is there a right way to teach A3? read more »
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Engineering Checklists
October 20, 2011Dear Gemba CoachHow do I apply standardized work to product development? read more »
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Are lean principles universal?
October 3, 2011Dear Gemba Coach,Can we really consider Lean principles as Universal? I am currently working on a case study about the tea industry. What we have is a very seasonal, perishable product supposed to be available in various format (tea bags, caddies, pouches). The suppliers being all in Asia the lead times are what they are and I do not even talk about EU regulations imposing all kind of constraints. read more »
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Should we have our own TPS "house"?
September 21, 2011Dear Gemba Coach,My management wants to build our own version of the TPS (Toyota Production System) house in order to standardize our lean approach. Do you have any advice on how to do this? read more »
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Why Create Poka-yokes—and Why Disconnect Them?
September 7, 2011I’m a manufacturing engineer and since I have started participating in kaizen workshops, I have noticed that production supervisors tend to disconnect some of the poka-yokes we’ve put in place in the machines. When I challenge them about this they argue that operators can’t run production and cope with ... read more »
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How Can Lean Take Root in a Crappy Culture?
August 31, 2011Dear Gemba Coach:I've done a lot of working with lean, and recently started my first coaching/consulting gig. And while I'd love to help by introducing people to flow, takt time, pull, and all the nifty lean tools and ideas, the most striking thing I've learned is how much hostility and mistrust exists among people. How can I help lean take root when the biggest problem turns out to be a crappy culture? read more »
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Takt Time Thinking for a Low-Volume High-Mix Company
August 23, 2011Dear Gemba Coach,Our company produces custom products that cannot be easily forecast in terms of when they will be ordered, and in what format. How can a company facing high-mix, low-volume, and unstable demand establish a production system that uses takt time? read more »
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Why Is Failure Key to Lean Success?
August 10, 2011Dear Gemba Coach,I am a LSS black belt working with a sensei to improve our performance. We conduct many workshops that get results, but the sensei focuses on only what we didn’t achieve. Although I understand the logic, I find this tiresome and difficult to explain to the teams. Many people have invested significant time and effort in improving things and end up feeling let down. How do I help the group deal with this? read more »
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Method vs. Tool
August 2, 2011Dear Gemba Coach, I think that TPM, JIT, SMED, Heijunka are methods and the 5S, VSM Kaizen are tools. Perhaps we could use the expression “solutions” to include both methods and tools? Where do you stand on this? read more »
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Performance versus costs, part 2
July 22, 2011Dear Gemba Coach,I’ve read your recent column on performance versus cost with great interest, as I believe we’re currently having a similar discussion at management level. Would you clarify further the difference you see between performance management and cost cutting? read more »
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Problems First and Positive Thinking
July 12, 2011A true test of lean leadership is when people start feeling positive about highlighting problems and tackling them with their colleagues, looking for innovative solutions to today’s problems. read more »
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Performance Versus Cost
July 5, 2011Dear Gemba CoachI am the continuous improvement director of a large hospital. We invested two years ago in a central machine to perform all the blood tests. Unfortunately, we have many technical issues with the equipment and we don’t know how to get the manufacturer to solve the… read more »
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How Often Should We Change Takt Time?
June 3, 2011Untitled DocumentDear Gemba Coach,How often should we change takt time?Deep question. The answer is: I don't know; it depends! Let's make sure we're on the same page on what takt time is. Takt time is commonly defined as daily work time divided by daily customer demand. The idea is to figure out… read more »
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Standards vs. Standardization
May 25, 2011Dear Gemba Coach,We’re often told that “there can be no kaizen without standards.” But when do you start when there are no standards? How do you standardize? And how about “just do it” kaizen?This is an intriguing question, thank you. I’d say that the first point… read more »
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How Do I Change the Culture?
April 29, 2011Dear Gemba Coach,I come from a company quite advanced in lean and I’ve joined a new firm as technical director. I’d like to apply lean concepts to the way we invest, but every one tells me I’d have to change the entire culture of the place, which I find daunting. Is that really… read more »
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Why is Flow Easy, and Quality Hard?
March 4, 2011Dear Gemba Coach,I’m the head of the lean program for an industrial company of 13,000 people worldwide. We’ve made tremendous progress increasing inventory turns, and now my CEO keeps asking me why quality is not progressing as fast. My lean team has become proficient at teaching flow… read more »
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Are You Pulling?
February 25, 2011Dear Gemba Coach, We’ve made a substantial effort in training all our operators to standardized work (SW)by deploying Training Within Industry(TWI) principles across all our sites. While we’ve had some good results, the level of discipline on SW is disappointing, and many cells… read more »
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Properly Applying Auto-Eject Isn’t Automatic
February 3, 2011Gemba Coach,I’m working on improving the design of our machines for lean manufacturing, and hear that an auto-eject feature can support this work. If this is so, can you clarify how? I was reflecting on this very question a few months ago, incongruously, as I was sitting at a table… read more »
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The Trouble with Lean Experts
January 26, 2011Dear Gemba Coach,I run a Lean Promotion Office(LPO) and my team mostly conducts kaizen events across the company. We are usually seen as successful in getting results and are well supported by our senior management. One problem is that middle-managers often complain about how individual LPOs go about effecting change, coming in with preconceived solutions, not listening to the people on the ground and sometimes adversely affecting operations in ways that don’t show up in the indicators. We see the lean program as quite successful overall, and have difficulties reconciling this with what we see is a worsening reputation. Have you come across situations like that? read more »
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How Do We Manage Our Stock to Be Lean AND Responsive to Varied Customer Demand?
December 22, 2010Dear Gemba Coach,We’re a tier two supplier and we’re trying to implement a pull system. We’re leveling our production schedules, but our customer’s variation in the demand for products immediately makes us miss shipments. Our OTD is not getting better. Although production… read more »
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Leveling to Build Capacity and Flexibility
December 14, 2010Dear Gemba Coach,We manufacture a seasonal product and are working on leveling, but are having a tough time. Our peak sales occur in a four-month time frame, but we need to use year-round production for capacity. Any advice on how to level what feels to us an impossible cycle?Your challenge is… read more »
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LEAN = TPS {KAIZEN + RESPECT}
November 22, 2010LEAN = TPS {KAIZEN + RESPECT} read more »
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How Do I Lead An Existing Lean Initiative as a Newcomer?
November 17, 2010How Do I Lead An Existing Lean Initiative as a Newcomer? read more »
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How Do We Help Our Plant Managers Want to Do Lean?
October 25, 2010How Do We Help Our Plant Managers Want to Do Lean? read more »
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How to Use Red Bins
October 14, 2010Dear Gemba Coach,We’re having an internal debate about how to involve the quality department and how to use “red bins.” Any advice? I’d have to know more about the specifics of your company to write a meaningful response, but I can share a gemba story of a plant that… read more »
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Role of the Sensei
September 29, 2010Dear Gemba Coach,Isn't Follow the Learner a story of improvement without a sensei? That isn't to say the journey described wouldn't have been faster with a sensei, but Dr. Bahri's practice has been successful. I often wonder how senseis skip to new areas--from the shop floor to the back… read more »
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Do We Need a Truck Preparation Area?
September 15, 2010Dear Gemba Coach,As logistics manager, I disagree with our lean expert who insists we should have “truck preparation areas” in the shipping hall. It adds more handling and goes against the lean principle of touching every container the least possible. As we have many trucks leaving per… read more »
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How Does Pull Relate to Problem-Solving?
September 9, 2010Dear Gemba Coach,I’ve been following the exchanges on The Lean Edge with great interest, and all the lean authors seem to focus on problem solving. In our company, lean has essentially been about implementing pull across the plants. Which way should we go?Your question captures a key lean… read more »
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How Can One Be A Better Sensei?
September 2, 2010Dear Gemba Coach,Our operations VP is disappointed with our lean program. Despite his close personal involvement with the program, it is not delivering the level of results he expects. How can he be a better sensei? Is this even the right question to ask? Both of your recent books stress the… read more »
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How Do I Clarify Lean Roles and Responsibilities?
August 22, 2010Dear Gemba Coach,Can you provide some guidance on splitting roles and responsibilities amongst the various hands-on leaders of the lean implementation (lean support group, operations managers, team leaders) in order to get the best mix of engagement and proper process?Hmmm …… read more »
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Standardized Work in Business Processes
August 11, 2010Dear Gemba Coach, How about standardized work in a business process environment? For example, in a procurement process or supply chain processes? There are not many books/articles on standardized work in a transactional environment. Please help to shed some light on how we should approach… read more »
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Standardized Work in Machine-Intensive Processes
August 4, 2010Dear Gemba Coach, Most lean literature and case studies to date focus on assembly type manufacturing which utilizes very people-intensive operations. This is not the case in the machine-intensive process industries and therefore has major implications on the format of standardized work. Can… read more »
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Making People Before Making Products
July 26, 2010Dear Gemba Coach,I keep hearing about “making people before making products” but I have a hard time visualizing what this means in practice. Would you be able to shed some light on this practice?I’ve spent the best part of the previous 15 years trying to figure this out and can… read more »
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What Should I Be Looking For?
June 30, 2010Dear Gemba Coach,I’ve just started working with lean with my team, and we’re doing a value-stream mapping project with a consultant. While this has been challenging, and eye-opening, and a great motivator for going to the “gemba,” I must confess something. I still… read more »
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How Do I Lead Change Without Discouraging Employee Engagement?
June 22, 2010Dear Gemba Coach,How do you balance the sometime conflicting practices of gaining employee engagement while ensuring that everyone remains faithful to known lean tools and principles? In other words, when a kaizen team arrives at a solution that you know to be flawed with respect to the… read more »
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Where to Start in Engineering
June 15, 2010Dear Gemba Coach,I’m in charge of the engineering department in our company and the CEO has asked me to start with lean. I’ve been reading the books and it seems very complicated and geared towards much bigger outfits than ours. I’m at a loss as where to start in practice –… read more »
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Standards at workstations
June 3, 2010Dear Gemba Coach,Our corporate production system asks us to post standard work at workstations, but we feel that the paperwork clutters the stations and operators tell us they don’t use it in any case. Should standards be posted at the workstation?Operators are most likely right. I… read more »
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How can we remain positive?
May 25, 2010Dear Gemba Coach I am a kaizen coach in a large company, and it never seems to get any easier. We’ve been doing kaizen for several years but people seem just as resistant, the problems we face are just as huge, and our sensei is never satisfied. I find it hard to remain positive, and am… read more »
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How lean should a lean line design be?
May 19, 2010Dear Gemba Coach,I’m in manufacturing engineering and have been asked to design a lean line. I’ve participated to several kaizen workshops and have some general ideas about how to go about it, but I’ve also heard many horror stories of lines that were designed so… read more »
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When should I push and when should I praise?
May 12, 2010Dear Gemba Coach,I am in charge of a service activity and have started a lean approach with a sensei. In our last gemba tour, one of my staff got very upset about the fact that we seem to point out only the negatives and never recognize all the good work they do. The area was a mess, and most of… read more »
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Should I pursue waste elimination or lead-time reduction?
May 6, 2010Dear Gemba Coach,We’re having a heated debate in our company over whether to pursue cost reduction through waste elimination by accelerating kaizen events, or whether to focus on lead-time reduction by implementing a pull system. It appears to me we’re not clear on the link between… read more »
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How Do You Find - or Develop - the Right Sensei to Lead Lean?
April 14, 2010Dear Gemba CoachI am struggling with the problem of training our leaders to become lean leaders. After a full year of doing lean at our company, it is clear that the individuals leading the effort have been transformed. While they were cautious at first, they are now asking many questions, and are… read more »
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How Do I Keep My Lean Team Motivated for the Long Term?
April 5, 2010Dear Gemba Coach,At the company where I am production manager, we've done lean for nearly three years. But my team is running into a real challenge when it comes to motivation. My team often feels that they are alone in their improvement efforts. Even after all our work we continue to encounter… read more »
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Is Toyota No Longer a Guiding Light?
March 9, 2010Dear Gemba Coach,I'm the lean manager of a mid-sized company, and have been getting teased by many folks about Toyota's troubles. It's mostly good-natured, but I fear the public flogging gives nay-sayers an argument for not doing lean. So I am unclear about how to respond to these critics. What… read more »
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How Does Lean Apply In a Job Shop?
February 25, 2010Dear Gemba Coach,In our job shop we make high precision modules and tools, work that involves a great deal of variety and very little repetition of products or processes. How can we apply lean principles in an environment like ours? read more »
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Lean in the IT Department
February 17, 2010Dear Gemba Coach,My company has been doing lean for a while now, and I've been asked to start lean in the IT department. I've read the books and gone to the conferences, but most of what I see is very focused on manufacturing. I'm unsure about where to start - would you have a few pointers?Lean and… read more »
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The Business Case for Kaizen
February 11, 2010Dear Gemba Coach,Our management team introduced kaizen events to our company three years ago. As a manager involved with lean, I have participated in many of these, and can say that a large number of managers are now able to run kaizen with our own black belts - without consulting support. Yet in… read more »
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Freedom
February 5, 2010Dear Gemba Coach,I work for a large governmental organization that has decided to do lean. I have been interested in lean for some time, yet am concerned about the current program: it appears as if our leaders intend to conduct across the board cost-cutting workshops to eliminate waste. This… read more »
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How Can I Convince My CFO?
January 29, 2010Dear Gemba Coach,In our manufacturing business, we have several opportunities for improvement that involve reducing WIP and excess inventory (of both purchased and fabricated parts). Is there a way to put a dollar value (cost savings) on these types of improvements? We have trouble gaining CFO… read more »
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Can Great Lean Companies Develop Great Lean Managers?
January 18, 2010I participated recently at a hiring process for a position at a lean company (a true leader in the lean field). They were about to fire a manager who had a bad attitude and was performing poorly. However, the company was handling this in what seemed like a fearful and excessively risk-averse… read more »
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Is Lean Scientific?
December 28, 2009Dear Gemba Coach,I often hear that lean is like the scientific method. As a lean consultant, I facilitate kaizen events, and find it hard to see the parallels. Could you clarify what people mean when they say this, and how it applies to our work?Thank you for this very fundamental question. It is… read more »
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What Role Should a Quality Department Play in a Lean Organization?
December 16, 2009Dear Gemba Coach,I really enjoy the passage (found on pages 29-30) in The Lean Manager where you discuss the relationship between a dedicated quality group and the overall quality system in a company. I'm thinking in particular of two quotes. The first: "I want you to shrink the quality… read more »
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How Come Toyota Veterans Don’t Use a Roadmap?
December 9, 2009Dear Gemba Coach,Recently I spent a few months working with Toyota veterans at an automotive supplier. I was surprised at their approach. I expected them to start with what I understood as the basic sequence outlined in books showing the TPS House: 5S, then stability in the 4M's, standardized work,… read more »
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Why does one-piece-flow matter?
December 3, 2009Dear Gemba Coach,I am value stream manager in a company that makes consumer goods. We have been working with a sensei for three years and have progressively moved from batch organization to flow and production cells. Recently, during the plant visit, our sensei made a big fuss because there were… read more »
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What Does Problem-Solving Look Like? Part 2 of 2
November 18, 2009Dear Gemba Coach:Thank you for explaining the different types of problem-solving that distinguishes lean. But how can I tell that we really are learning the best way to deal with problems? What are the signs of progress when it comes to problem solving? Good question - and thank you for your… read more »
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What Problems Are Lean Practices? Part 1 of 2
November 11, 2009Dear Gemba Coach,I keep reading that lean is about solving problems. But that's exactly what I already do in my job. So how is lean different?That's a very good question. To explore this issue more deeply, let's start by clarifying exactly what we mean by "problems." Let's distinguish… read more »
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Do Managers "Get" Lean?
November 5, 2009Dear Gemba Coach,You mentioned during the webinar that plant tours reveal how well managers 'get' lean. Can you be more specific?Certainly. One of the key purposes of practicing "go and see" is to examine the current state of gemba leadership. After every workplace visit I will ask senior… read more »
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How can firing people be part of developing people?
October 28, 2009Can you explain how you reconcile the principles of "developing people" and "firing people," especially in light of the challenges illustrated in your book The Lean Manager? Why, on the other hand, does Toyota try to keep its employees as long as it can?Well, this is an… read more »
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Where do I start?
October 21, 2009Dear Gemba Coach,I'm the operations manager of a healthcare training company. We conduct technical training to nurses in hospitals. The president does the commercial part, and I run the operations, which is now an office of seven that coordinates the paperwork with hospitals, the logistics of… read more »
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Lean and Financials
October 14, 2009Dear Gemba Coach,During the webinar, you mentioned the importance of quantifying the financial impacts of lean efforts before introducing the system. This is a very common obstacle. Please go into more details about how to do this. This is indeed a common problem, and a difficult one to solve… read more »
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How Do I Convince People to Practice Lean?
October 7, 2009Dear Gemba Coach,I have previous lean experience, and have now joined a large bureaucratic organization. I’m trying to apply the lean approach, but the management team and business culture remains stubbornly public sector in their thinking. Any advice on how to crack this issue?To start with,… read more »
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Kaizen is Fun? Really?
September 30, 2009Dear Gemba Coach,I have been learning lean for three years now. My question to you: How is Kaizen 'fun'? Doing lean shakes people out of their comfort zone and challenges everything they believe about their work. Kaizen demands that they constantly improve what they do, and by implication,… read more »
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How Can I Address the Conflict that Lean Creates?
September 28, 2009Dear Gemba Coach, I have just finished reading The Lean Manager, and I was very taken by the chapter on teamwork. I am a lean officer in a bank and have been working with back-office processes for the past two years. We have had good successes on the sites, but the general feeling is that lean has… read more »
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Managing Suppliers
September 16, 2009Dear Gemba Coach,We've done a lot of kaizen work in production and have something of a pull system running. We've started measuring on time delivery at every step of the process, and it appears that suppliers account for a large part of our instability. Should we extend the kanban to the suppliers?… read more »
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Signs of Progress
September 9, 2009Dear Gemba Coach,Q: We've been doing lean for several years now, and the program has had its ups and downs. What are the signs that one should look for that indicate progress on lean work?A: This is a very good question, and not so easy to answer because lean happens at many different levels, and… read more »
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How Do We Reduce Costs with Lean?
September 1, 2009Dear Gemba Coach:This will be a very general and basic question. We build a large product that several weeks to complete. We fabricate some things in-house and others outside. Currently no form of Lean exists. I have been asked to reduce the cost of a product by a significant amount. I believe that… read more »
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How Much Control Do I Need (and Need to Give Up) to Lead?
August 26, 2009Dear Gemba Coach: I am interested in setting up a team for implementing lean. So far I have been trying to make changes on my own, but find that without support from others I have little time to implement new practices or conduct root-cause problem-solving. Doing so keeps me from running the daily operations of the fabrication and large machining departments. To be an effective lean leader, do I need to let go of the control of the daily operations and concentrate on being the lean manager? read more »
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Who To Move?
August 19, 2009Dear Gemba Coach:"Kaizen Express" landed on my doormat this morning. While reading through I noticed that it states that if you get an operator saving through a kaizen you move the best, most experienced operator out of the team.Has anyone had any success with this?I know that I was never… read more »
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5S Again and Again and Again
August 7, 2009Dear Gemba Coach:Q) I've just inherited responsibility for our 5S efforts in our company. And I face a huge challenge getting the program back on track.Last summer, a consultant launched a big 5S program with an internal lean Champion. We had great results for the first few months. But the… read more »
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