Jon Miller, Author at Gemba Academy

The 1950s Movie Guide to Lean Service

By Jon Miller - July 15th, 2009

Ah, those irony-free halcyon days of naming films for what they were… The challenges facing the service business attempting to practice lean principles bear an uncanny similarity to those confronting the hero of a bad 1950s scien

When Automation is Stupid

By Jon Miller - July 11th, 2009

I don’t know how many times I’ve passed through this section of Narita airport. Only yesterday did it strike me how stupid this moving walkway was. It is all of 18 paces long. Hardly worth breaking your stride to step onto,

How do You Say “‘No problem,’ is a Problem” in Romanian?

By Jon Miller - July 9th, 2009

A friend of mine recently took a position in an electronics factory in Romania. He sent me an e-mail and the photo above. One day he came in to work to find this sign on his computer. It says “We don’t have a problem, only

The Power of U

By Jon Miller - July 8th, 2009

My Japanese teachers often spoke about making processes flow “like a single brushstroke”. It was and still is a phrase difficult to translate. Often I would mimic picking up a calligraphy brush and sweeping it in a u-shape

One Point Lesson: Kamishibai

By Jon Miller - July 6th, 2009

Prof. Jeffrey Liker has uploaded an excellent slideshow from 2005 titled The Toyota Way: A Sociotechnical Learning Organization in Action. The image above is from this presentation in which Liker touches briefly on the kamishibai board

Boeing Gets a Grip

By Jon Miller - July 2nd, 2009

…on its supply chain, according to a Wall Street Journal article from July 2nd, 2009. Boeing is in talks to buy Vought and possibly other suppliers in an attempt to gain control over the supply of parts. It’s about time lea

Saluting NUMMI

By Jon Miller - June 30th, 2009

The New United Motor Manufacturing factory in Fremont, California was originally a General Motors plant opened in 1962. For the past 25 years it has been a successful joint venture between GM and Toyota. Bloomberg reports their uncerta

Agile Kanban Journal Day 8: Do We Need a “Done” Column?

By Jon Miller - June 29th, 2009

I continue to benefit from the use of my Agile kanban board, if nothing else to keep my supposedly most important tasks in front of me (or behind me as it were, per layout of the office). I have faith and confidence that using this met

Seeking: Checklist for a Sense of Urgency

By Jon Miller - June 25th, 2009

“The most important factors for success are patience, a focus on long term rather than short-term results, reinvestment in people, product, and plant, and an unforgiving commitment to quality.” This is a quote from R

The Funny Thing About Waste

By Jon Miller - June 23rd, 2009

The funny thing about waste is that it’s all relative to your sense of scarcity. At least that’s how a Wired magazine article by Chris Anderson titled Tech Is Too Cheap to Meter: It’s Time to Manage for Abundance, Not

Agile Kanban Journal: Kaizens on Day 1

By Jon Miller - June 22nd, 2009

Kaizen emphasizes making small changes every day and retaining the ones that bring positive outcomes. With the help of friends, my agile kanban board evolved on its first day of use. After organizing my projects and tasks on an erasabl

Trying Out My Agile Kanban Board

By Jon Miller - June 19th, 2009

One of the biggest challenges of doing kaizen in office work is to make the work itself visible so that waste can be clearly identified. Much of the time spent in office work is finding files or information, switching between tasks, fi

The Amazing Adventures of Kanban

By Jon Miller - June 17th, 2009

Kanban was born nearly 60 years ago. It’s creator, Taiichi Ohno, intended kanban to combat the evil overlord Overproduction, Mother of All Wastes and her Minions of WIP. The battle is far from won. During those six decades kanban

There is No Such Thing as Wasteful Work

By Jon Miller - June 16th, 2009

I read an interesting article today in the Japanese paper Nihon Keizai Shimbun. The topic was how white collar businesses men in Japan are adapting the Toyota Production System, or what we would call lean thinking, to their work. The c

Free Gemba Academy Video: The 7 Deadly Wastes

By Jon Miller - June 11th, 2009

It has now been three months since we launched Gemba Academy – the online learning center for continuous improvement. Each month we add new videos, quizzes, self-study materials and forum discussions. The School of Lean is curren

Review of Follow the Learner by Dr. Sami Bahri, DDS

By Jon Miller - June 10th, 2009

Follow the Learner: The Role of a Leader in Creating a Lean Culture by Dr. Sami Bahri, DDS is the best book on the subject of leadership and lean I have read in a long time. Written as a very personal account of the development of teh

How to Engage People in Kaizen

By Jon Miller - June 9th, 2009

As always, thank you for your questions, comments and improvement suggestions. Today one of our readers shared via email a challenge with getting people engaged in kaizen. Whether it is an improvement suggestion system, a software syst

What is the Role of a Kaizen Promotion Officer?

By Jon Miller - June 2nd, 2009

Raghavendra asked, “What is the role of a kaizen promotion officer?” I have never been in a kaizen promotion office (KPO) but have worked with and round them for many years. At worst the KPO is a coordination, preparation,

9 Ways to Struggle at Hoshin Kanri

By Jon Miller - May 31st, 2009

Hoshin kanri is what happened when Management by Objectives met TQC. In essence it is the thorough application of the PDCA cycle to the strategy development and execution process. There are some unique aspects to hoshin kanri due to th

Ambiguous Visual Controls: This is Elite Access

By Jon Miller - May 22nd, 2009

Thanks go out to Bill Sampson, a lean six sigma consultant and friend of mine for snapping this photo of an ambiguous visual control in an airport boarding area. This attempt at visual management raises more questions than it answers.

Tsurube System: How to Flow through Shared or Batch Equipment

By Jon Miller - May 20th, 2009

One of the inevitable consequences of 5S activity is that you find out that you don’t need some of the things you have, and that you don’t have some of the things you need. More often than not, you also find things you have

5S Red Tag Event for this Website

By Jon Miller - May 17th, 2009

Thanks to a reader’s timely comment, I am happy to share with you some news about some accelerated change to our blog. “The site looks like it needs a red tag event!” said Shaun. Right you are! What surprised me was t

8 Ways to Get Total Involvement

By Jon Miller - May 13th, 2009

There was an inspiring article by Pete Abilla on the Shmula blog yesterday called Total Company Involvement. In any company-wide continuous effort, there are various levels and degrees of employee engagement. In a true high-performance

One-point Lesson: One-point Lesson

By Jon Miller - May 11th, 2009

Sometimes we are so busy that we think we don’t make time to develop the people around us. Instead we fight fires or give direct instructions. This might be effective in the short-term but inevitably small problems are missed. Th

A GPS for the TPS

By Jon Miller - May 5th, 2009

One of the common objections we hear to doing kaizen is that “We’ve tried it before” and it didn’t work. It’s amazing that this could ever be a reason for people to stop trying, yet it is. Last summer I sp

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