Jon Miller, Author at Gemba Academy

Six Degrees of Taiichi Ohno

By Jon Miller - October 26th, 2010

I was recently asked my view on an idea going around the community of lean thinking people. This notion goes that in order to be a sensei one must be separated by no more than two or three degrees from Taiichi Ohno. Without any disresp

The Smallest Steps Towards Quality Improvement

By Jon Miller - October 24th, 2010

There is a story about a consultant, apocryphal perhaps, who charged $10,000 for putting a chalk mark on the part of a machine that was causing big problems for his customer. When the customer complained that the charge was excessive f

Practical Pokayoke: Preventing Phone Charger Loss

By Jon Miller - October 19th, 2010

This is an example of a great pokayoke (mistake proofing). My road warrior colleague Kent is prone to forget his phone charger, leaving them plugged in when he departs. The photo above shows the simple yet brilliant application of the

Ambiguous Visual Controls: Lost in the Supermarket

By Jon Miller - October 16th, 2010

Visual controls must at the very minimum be unambiguous, and either indicate normal versus abnormal or to positively specify a problem condition in order to be useful. Ambiguous visual controls are a waste of print and only good as exa

Blog Action Day: Water

By Jon Miller - October 15th, 2010

Most of us take water for granted. It is colorless, tasteless and runs within, on or around our bodies every moment of our lives. Water flows and forms around obstacles, freezes and cracks the hardest stone, evaporates and floats away

Waste Rules the Empty Spaces Between Us

By Jon Miller - October 13th, 2010

The latest episode in the chronicle of the lean journey at Group Health Cooperative in Washington State is A Story from the Front By Dr. Wellesley Chapman. Dr. Wellesley writes about the experience of launching the lean transformation

10 Mistakes in Starting Lean Enterprise Transformations

By Jon Miller - October 11th, 2010

The are plenty of mistakes people can make when starting up a lean enterprise transformation. Interestingly, many of these mistakes are similar if not identical to those entrepreneurs make in starting a business. Perhaps these mistakes

Wasting Time in 3 Billion Meetings

By Jon Miller - October 8th, 2010

Meetings are one of the few times when humans have the opportunity to positively and constructively interact with one another, yet it seems businesses and organizations large and small struggle to make them effective. In fact often mee

The Engine, the Oil and the Fuel

By Jon Miller - October 6th, 2010

A lean facilitator from France asked a question about how lean transformations should be driven. This person’s company started lean in 2007 by having a sensei within top management. The background is: I was named lean facilitator

Shifting Care to the Front Line

By Jon Miller - October 3rd, 2010

An article in the October 2010 issue of the Scientific American titled “Closing the Healthcare Gap” revealed the importance of primary care physicians in improving the healthcare system and also the problem of a shortage of

Bring on the Learning Revolution!

By Jon Miller - October 2nd, 2010

My friend Ted is always spreading good ideas. This 18 minute video titled “Sir Ken Robinson: Bring on the learning revolution!” was delivered with skill and humor, bringing home some ideas that have interesting parallels wi

Thank You for Saving Energy

By Jon Miller - September 29th, 2010

Junaid shared with us a simple energy savings idea he took away from a study trip to Japan: I learned many things from Japanese society energy saving is one of them which we have implemented in our factory in Pakistan. I was really imp

Lean Thinking and The Little Prince

By Jon Miller - September 28th, 2010

Sometimes life feels as hard as passing an elephant through a boa constrictor. French writer and aviator Antoine de Saint-Exupery (1900 – 1944) left us with a charming novella, The Little Prince. Perhaps opening this book again w

Cross Training, the Johari Window and Kaizen

By Jon Miller - September 27th, 2010

Within a lean work system the practice of job rotation serves the purpose of cross training and increased flexibility. This can be deliberate and time-based for repetitive manual work, such that people switch from one task to another e

Is Too Much Money Worse than Too Little?

By Jon Miller - September 24th, 2010

An old friend of mine who has run a small construction company for decades reflected back on his career as he nears retirement, “If I’d been rich I think I would have done many bad things.” He was probably talking abo

Stealing the 7 Secrets of Toyota’s Business Success

By Jon Miller - September 22nd, 2010

Taizo Ishida (1888-1979) took over the role of President of Toyota from the inventor and founder Kiichiro Toyoda in the midst of labor unrest, layoffs and the threat of bankruptcy. Ishida is considered the “restorer of ToyotaR

Possibly the Worst Ever Use of a Suggestion Box

By Jon Miller - September 20th, 2010

A September 20, 2010 New York Times article title Haitians Cry in Letters describes what happened when suggestions boxes were set up recently at the 1,300 camps for refugees of the earthquake in Haiti. The letters in the boxes are not

Bridging the Knowing-Doing Gap

By Jon Miller - September 16th, 2010

One common theme from the lean tours we led here in Japan this week was that all of the organizations we visited have successfully bridged what is called the knowing-doing gap. Popularized by Stanford University professor Robert Sutto

How to Sustain a Lean Culture after 10 Years

By Jon Miller - September 15th, 2010

This week I am in Japan helping to lead one of our lean manufacturing benchmarking trips. What I took away from the debriefing from yesterday’s lean benchmarking visit was a series of lessons on how to sustain a lean culture afte

Still Learning the Meaning of Cleaning

By Jon Miller - September 14th, 2010

Just when you thought you knew all you needed to know about cleaning the workplace as part of lean manufacturing, the universe sends you a day like yesterday. We visited a small, privately held company in rural Japan. This company was

Energy Savings Kaizen: Switch on to Use

By Jon Miller - September 13th, 2010

This week we are leading a big group on a lean manufacturing study mission in Japan. We call it the Japan Kaikaku Experience because we learn from companies that have gone through or are still going through kaikaku , a lean business tr

Lean Manufacturing and the Brain

By Jon Miller - September 11th, 2010

This week I learned that within the three pounds of spongy flesh that is the human brain there are 1.1 trillion cells, 100 billion neurons and 10 x 10 to the millionth power of possible neuron connections. This number makes my brain hu

Here It Comes, the Lean Burrito!

By Jon Miller - September 9th, 2010

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Why Salmon Would Fail at Hoshin Kanri

By Jon Miller - September 8th, 2010

While cleaning out my pockets after a long summer of travel I found “hoshin is like salmon” on a bit of improvised note-taking paper, in my handwriting. If it was important enough to write down, the meaning of this scrawl s

Leaders Pull

By Jon Miller - September 6th, 2010

Leaders lead. Or do they? There is not always a cause and effect relationship between leadership actions and follower behavior. Not all leaders succeed at pulling people along in the same direction. If a leader needs to drive people in

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