Lean Marketing House » Lean six sigma

Driving Profit through People and Processes

admin — Fri, 06 Apr 2012 02:38:00 +0000

This is a transcription of the Business901 Podcast, People & Process Drive Profit Podcast with Vivian Hairston Blade, Founder, President & CEO of Experts in Growth Leadership Consulting, LLC (EiGL Consulting, LLC) based in Louisville, KY.

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Vivian is a recognized expert, keynote speaker, trainer and executive coach in the principles of Customer Experience, Lean Six Sigma and Leadership Development. With a 20+ year career in Fortune 100 companies, General Electric and Humana, Inc., Vivian has extensive experience in successfully leading the development and execution of customer centered, quality-based, growth business strategies.

PDCA Cycle of Zingerman’s Deli

admin — Fri, 16 Mar 2012 03:30:00 +0000

At the 2011 ASQ Lean and Six Sigma Conference, one of the featured speakers was Ari Weinzweig, CEO and co-founding partner of Zingerman’s in Ann Arbor, Mich. The Zingerman’s Community of Businesses (ZCoB) has annual sales approaching $40 million. ZingTrain, a consulting and training company that shares Zingerman’s approach to business with like-minded organizations from around the world, and offers a variety of management training seminars in Ann Arbor, as well as customized workshops and presentations at client sites.

Fellow Lean Blogger, Mark Graban wrote a recap Management Lessons from Zingerman’s CEO Ari Weinzweig of Ari’s talk. I encourage you to read it. What I wanted to share was my personal experience of Zingerman’s Deli. Besides the great food and great service and catalog littered with special gifts and even more unique food, Zingerman left a special mark on a venture into the retail business that my wife and I did for six years. It was Ari’s book,Zingerman’s Guide to Giving Great Service, that provided our outline for the service that we would provide and train our staff. Below is a mind map of the initial outline that I constructed from the book.The second mind-map is what I would call an ad-hoc representation of the Zingerman’s PDCA cycle: Define, Teach, Live, Measure, Reward. I find the Zingerman model an excellent guideline for our and other retail operations. In fact, very few things are difficult to do, it is just a matter of doing it.

P.S. I was unable to attend this conference as I was on the other side of the county in Orlando at the ISO9000 Lean and Six Sigma Conference.

Lean and Six Sigma training to deployed Soldiers

admin — Tue, 13 Dec 2011 03:32:00 +0000

Just received a copy of an article, Resolute’ brigade provides Lean Six Sigma training to deployed Soldiers from Tim Fowler, a CPS Professional Services contractor assigned to Task Force Resolute at Kandahar Airfield, Afghanistan. Tim is teaching a group of U.S. Forces about Lean and Six Sigma. They are applying this training immediately through improving the logistics capabilities of the command. More information can be found in the article.

Quote from the article:

“Through Lean Six Sigma, soldiers and leaders will learn how to properly manage time and resources while delivering a top quality product the first time,” said Chief Warrant Officer Jackie Vuorinen, the TF-Resolute safety officer. “This is a program all soldiers can use to save Army resources while providing higher quality products.”

Tim appeared on the Business901 podcast, Are right brain thinkers better leaders? Tim is a University of Kentucky Certified Lean Master, a Goldratt Institute Theory of Constraint Supply Chain Expert, an ASQ-Certified Six Sigma Black Belt, and a Licensed Social Worker with a SECRET clearance and his website, BusinessLeadership.com is a popular venue for leading edge thinking.

Thanks Tim for passing this on and wish you and everyone else at Kandahar Airfield a safe and Happy Holiday!

Lean or Six Sigma which fork in the road do you take?

admin — Thu, 01 Sep 2011 02:44:00 +0000

People will see my comments floating around the Internet on the subject of Lean Six Sigma. I am not an expert and probably take too much liberty in the application of them to even proceed but it was important to me to basically post my view.

There will always be a strong debate between Lean and Six Sigma people about using the 2 terms jointly. I am not positive of the lineage of it but I believe Michael George at the time of the George Group (later to be Accenture) coined the term. I assume he viewed the two methodologies as compatible and more effective in conjunction with each other versus separately. I am not even sure that many (Case in point being that many of today’s “Lean” consultants were trained as Lean Six Sigma Black Belts) disagreed at the time except for the very traditional Lean stalwarts.

Dr. Mikel Harry, credited as one of the founders of Six Sigma states that Six Sigma is not a culture and was developed as a quality tool to gain breakthrough performance for an organization. I adhere to that statement and think Six Sigma offers great opportunities for an organization and provides a very precise and workable structure in achieving this. I am not against the hierarchy of belts and the formalities of DMAIC, DFSS, etc. Many organizations need this type of structure to be successful. I am avid defender of Six Sigma in the Lean circles many times to the chagrin of others.

Lean was developed by the MIT group under Dr. James Womack from a study of automotive companies and more specifically the Toyota Production System. Its approach is based on continuous improvement with a direct correlation to PDCA and Dr. Deming’s philosophies. Lean made its first inroads in many companies and gains in popularities (IMHO) because of the ease of entry into the methodology. Removing waste and improving flow was Lean’s mantra in the 90’s and the tools of 5s and Value Stream Mapping soared in popularity. However, as Lean continued developing tools of A3, Hoshin and Standard Work became common place. But even more so, the culture of PDCA and the spirit of Kaizen started to take hold.

Six Sigma was the methodology of choice for many manufacturers as a result of the significant strides that GE and Motorola had made. Later, Lean seemed to gain and Six Sigma wane in popularity. Lean became the path to a customer as an enabler of some quick wins. You could then take the deep dive with Six Sigma when you wanted to get “serious”. As Lean continued to steamroll and Six Sigma still continued with somewhat lackluster performance many organizations and consultants dropped the attachment to Six Sigma and became “Lean”. Popularity does create a crowd. This may not be an entirely accurate description but it serves as a basis for my views and the following comments.

What makes Lean Six Sigma work? When you first start using any methodology, you are typically introduced through the tools. Using Lean initially versus Six Sigma makes perfect sense, it is an easier introduction. And why reduce variability on non-value activities? But sooner or later you get to the fork in the road. One path says Six Sigma and the other path is this thing they call culture (Lean). So do you want to take the deep dive with a breakthrough structured approach (still has a steep incline) or do you want to try and instill a culture of empowerment. There is not a right or wrong answer. You can take either. Where I disagree, is that you can take both.

Six Sigma has always been about structure and tools. It is very, very good and does an outstanding job when applied properly. In Six Sigma thinking, you can use Lean tools initially and get to 95%. To finish the job, you use Six Sigma. And as a result, Lean Six Sigma was developed. If your organization grew out of the Motorola and G.E. world it seems like a perfect fit.

If you adopt the Lean mentality and the spirit of Kaizen (continuous improvement is not an event) you become immersed in the culture of Lean, as Dr. Balle wonderfully described in the Zen Story about the mountain. Summed up in the blog post: Lean Tools and Culture as it Relates to Zen

Have you ever played yourself in a game? On a basketball court or even a simple game of checkers, sooner or later you have to pick a side to win. It is inevitable. This is the ultimate wedge between the two methodologies and can simply be stated. Six Sigma is a structured methodology and Lean is a cultural driven learn by doing approach. That is not to say that Six Sigma does not have its prototyping options and that Lean is not without statistical control (it did evolve from Deming). But it is saying that they are both on two completely different paths that you must choose between.

If you take the path of and see Lean as Lean, Six Sigma does not make sense and is not a compatible technology. There is a significant culture difference and approach. If you take the path of Six Sigma, you view Lean as only a set of tools nothing more and why not, Lean has a great toolbox. If you take the path of Lean you still can be just as efficient and just as effective as Six Sigma, you just do it differently.

I make no qualms about stating that I believe and follow a Lean philosophy. Lean works in my world much better. PDCA which is basically form a hypothesis, test it and adjust is what sales and marketing is all about.

I support the idea of Lean Six Sigma without hesitation. What I have trouble understanding is how you can be philosophically aligned in Lean thinking and practice Six Sigma. So I believe you must ask yourself; Which fork in the road do you take?

Marketing with A3 Book Release

admin — Fri, 21 Jan 2011 19:15:00 +0000

Sales and Marketing not only needs to improve but must improve their problem solving skills. The book, Marketing with A3 is the introduction needed. It enables sales and marketing to use the Lean tool of A3 as a template or structured approach for their strategies and tactics. It will also demonstrate meaningful and measurable results of their activities. You will enter meetings armed with facts and profound knowledge of sales and marketing efforts. As a result, you will engage in more meaningful conversations. It will require a different approach. The dialogue is sometimes not easy. But seldom is any improvement.

Using a structured approach, such as the Lean thinking tool of A3, the mind remains open, enabling one to examine each element of the decision or problem separately or systematically, and sufficiently, ensuring that all alternatives are considered. The outcome is almost always more comprehensive and more effective than the instinctive approach.

Visit the Marketing with A3 Website

Sample A3s

A3 Podcasts

A3 Community

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You can implement Poka-Yoke

admin — Wed, 22 Jul 2009 02:55:00 +0000

These are the the tools I use for Poka-Yoke Implementation. It will make you as “Smart as a 5th Grader.” Yes, this is not rocket scientist stuff. It is easy and simple. Now, these methods alone will not get you to Six Sigma Quality levels but they will start you on the path of continuous and measured improvement. So what are the tools?

The first tool I use may not be considered a tool at all, it is a mind set, This is NOT WHAT to DO. I keep this diagram around and embed it in most of things that are printed. It is very simple but the key to making a successful Poka-Yoke campaign.

The Fishbone Diagram is a graphical compilation used to identify and explore the possible causes which lead to a given mistake. The ultimate aim is to work down through the causes to identify basic root causes of a problem. Related Blog Post.

Organize your mistakes(errors) and group them according to the Matrix. This will simplify the selection process on what mistake to tackle first.

I also have a list of Common Red Flag Conditions. These are quick places to look to assist you in finding the reason for the defect. You could maybe determine these to be your first “WHY” in your search for the root cause. The only thing I would warn you is not to jump to a conclusion. Insert a few these into your fishbone and go through the steps. Use at a brainstorming session to get those ideas flowing.

Frequent changes to a job
Complex processes
Lack of Standards
Lack of measurement systems
Lack of training
Long cycle times
Infrequent jobs
High output
Environmental conditions
Attitude ( Motivation)

The one tool that I left is the project sheet. We will start completing the components of this in the next blog and start creating a Poka-Yoke process in it’s entirety.

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