Jon Miller, Author at Gemba Academy

How to Scold Like a Kaizen Sensei

By Jon Miller - March 28th, 2010

There must be people at Toyota waking up in a cold sweat these days from dreams in which they are being scolded by Taiichi Ohno, furious at the massive vehicle recalls caused ostensibly by the pursuit of scale and volume production at

10,999,950 More Reasons to Think “Yes We Can”

By Jon Miller - March 25th, 2010

Sooner or later everyone involved in leading change faces naysayers and passive resisters. With the power of their minds these people add friction to the PDCA improvement cycle, noise in the signal of root cause analysis, and turbulenc

National Public Radio to Feature Lean Thinking and NUMMI

By Jon Miller - March 23rd, 2010

This Saturday March 27, 2010 the NPR program This American Life will feature the story of the Toyota-GM join venture factory in California in an episode titled NUMMI. Here is a promotional blurb from the NPR website. The story of a car

The Three Indispensable Qualities of a Lean Leader

By Jon Miller - March 22nd, 2010

Recently an old friend asked me to recommend a curriculum for certifying the lean leaders within their company to a more advanced level. The basic requirements for leading lean implementation, as with any change effort, are fairly stan

There is No Such Thing as Sustainability

By Jon Miller - March 20th, 2010

One of the finds during my ongoing spring cleaning at the Gemba office was an article with quotes by outdoor clothing and equipment company Patagonia founder Yvon Chouinard, with references to his book Let My People Go Surfing: The Edu

Kaizen Song: Change Agents

By Jon Miller - March 18th, 2010

This kaizen song is inspired by and dedicated to each of the men and women, young and old, with whom I have been fortunate to learn about what it takes to make change happen. Change Agents (to the music of Changes by David Bowie) I did

When to Shift from "Why?" to "How?"

By Jon Miller - March 16th, 2010

A recent problem solving team activity made me aware of the importance of knowing when to shift the conversation from “why?” to “how?” To be honest it is sometimes hard to know where to draw the line in the 5 wh

Run is to Milk as Spider is to…

By Jon Miller - March 14th, 2010

A pair of questions about lean logistics over the past few weeks prompted this post. Santosh from India asked “what is the milk run method?” The Milk Run The milk run is an example of time-fixed, quantity variable replenish

What You May be Missing About 5S

By Jon Miller - March 11th, 2010

Paul left a couple of comments recently that caught my attention: HELP! My company has been “attempting” 5s for several years now,and have recently begun rolling it out once again after stopping it a few years back. My prob

Peter Drucker’s Impact on Lean Thinking

By Jon Miller - March 9th, 2010

The spring cleaning continues. My research library is an embarrassment of riches. Old notes and unfinished files hide in the shame of abundance. More the worse, no matter how much knowledge is shared its abundance only increases. Lucki

Checking the Plan: Toyota Way 2001

By Jon Miller - March 2nd, 2010

Interesting articles of information continue to surface as the spring cleaning progresses at the Gemba office. Today’s find was a page from an interview with Fujio Cho. As the CEO of Toyota he had summarized the the desired ways

The Wisdom within the Experience

By Jon Miller - February 28th, 2010

We enjoy the freedom of speech and a free press. The accessibility of self-publishing and distribution of news and opinions due to blogs and internet journals has removed barriers to entry of the would-be journalist and columnists. As

Senate Candidate Paul Akers Preaches Lean on Fox News

By Jon Miller - February 26th, 2010

Wow.

Questions About A3 Problem Solving

By Jon Miller - February 25th, 2010

These days if you stand next to a Toyota building and listen closely you may hear the sound of many sheets of A3 sized paper being slowly turned into problem solving documents. There are a few big, complex problems that will surely res

Review of A Fine Line by Hartmut Esslinger

By Jon Miller - February 18th, 2010

On the recommendation of Matthew May, author, speaker and consultant to blue chip companies on innovation, lean and change, I read A Fine Line: How Design Strategies Are Shaping the Future of Business. Written by Hartmut Esslinger, fou

Excerpts from An Interview with Taiichi Ohno, July 16, 1984

By Jon Miller - February 16th, 2010

One of the rewards of last week’s office kaizen activity at Gemba was the discover a copy of the 1984 interview with Taiichi Ohno. The original paper An Interview with Taiichi Ohno, July 16, 1984 is in Japanese and can be found o

Kaizen Goes Kaput? Not So Fast

By Jon Miller - February 13th, 2010

In recent weeks there have been many articles purporting to put the finger on the cause for Toyota’s quality troubles. Most of them are solution-jumping and not worthy of further exposure or response. I felt compelled to address

Gemba Research Office Layout Kaizen #11

By Jon Miller - February 11th, 2010

Over the past week we have been chipping away at some office kaizen at the Gemba Research office near Seattle. The major activities so far have included a layout change, some 5S and other small improvements. In the 6 years that we have

How to Make Time for Kaizen

By Jon Miller - February 9th, 2010

In the early stages of exploring kaizen and other formal continuous improvement systems people always ask, “Where will we find time for kaizen in addition to all of our other work?” Ideally kaizen should be something done n

We Learn Nothing from History

By Jon Miller - February 2nd, 2010

Even as Toyota mops up the mess from their sales volume-driven expansion-related quality problems, challenger Volkswagen AG “…unveiled an ambitious plan to boost annual sales to eight million vehicles in the midterm and to

What Lean is Not and Never Will Be

By Jon Miller - February 1st, 2010

Industrial anthropologist, best selling author and eminence grise John Shook wrote a thoughtful column on the recent debate around what lean means and where we need to go next. He concludes that lean has always been about Toyota but no

Former Toyota Quality Manager’s Thoughts on Historic Recall

By Jon Miller - January 28th, 2010

This does not seem like the Toyota we know. The latest recall from Toyota related to its faulty accelerator continues to expand. Toyota has stopped sales of eight major models in the U.S. and the jury is still out as to how far this wi

Seven Sayings for Successful Continuous Improvement

By Jon Miller - January 27th, 2010

Getting started with continuous improvement is easy but keeping it going is hard. Even though we speak of long-term thinking as one of the central tenets of continuous improvement and kaizen, many of us opt for the short-term actions,

LEI Brings the Healthcare Gemba to You, Virtually

By Jon Miller - January 24th, 2010

Way back in the day when I was traveling all over the country as an interpreter for Japanese consultants I imagined what it would take to remove the non-value added part of this process: the travel. I imagined a the Japanese sensei wal

Review of “Work the System” by Sam Carpenter

By Jon Miller - January 21st, 2010

The title of Sam Carpenter’s Work the System: The Simple Mechanics of Making More and Working Less is deceiving. It sounds like another “4 hour workweek” promise-of-personal-wealth-and-happiness book of the moment. In

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