Gemba Academy

Accountability for Continuous Improvement

By Jon Miller - March 16th, 2009

Last week a reader by the handle of CILean asked Gemba: I have trouble with staff who appear generally supportive of improvement projects and agree with Senior Management on proposed actions but then fail to implement agreed changes an

It’s Officially On: Gemba Academy Launches

By Ron Pereira - March 15th, 2009

Note, this post was originally written on March 15, 2009. See what Gemba Academy looked like back then. After many, many hours of PDCA (plan, do, check, act) the time has finally arrived for Gemba Academy to officially open its doors f

Gemba Academy Preview: Calculating Takt Time

By Jon Miller - March 15th, 2009

Gemba Academy opens for enrollment on Monday March 16th, 2009. In the coming months we will offer online training on topics on a wide range of business excellence topics from lean manufacturing, project management, six sigma and other

An Electrically Delicious Lesson on Kaizen

By Jon Miller - March 14th, 2009

What would you do if given a do-or-die mission to create a battery out of simple, non-toxic materials, from a sustainable source, without using specialized equipment, with the added requirements that said battery must prevent scurvy an

The Greatest in the Kingdom

By Ron Pereira - March 12th, 2009

I was recently reading my all time favorite book and came across some comments that caused me to ponder a few of the articles I’ve recently written about being an expert and how many hours it takes to become an expert. Here’

Should Cross-trained Workers be Paid More?

By Jon Miller - March 12th, 2009

“Now that I can perform more tasks, pay me more.” This was the statement that an HR manager was struggling with recently at a company that is in the midst of introducing cross-training for multi-skilled operators as part of

5S Overview Video

By Jon Miller - March 11th, 2009

The launch of our online training service Gemba Academy is just days away. We have been busy at work readying online training courses for lean manufacturing, six sigma, project management and more. We will offer six month subscriptions

An Expert State of Mind

By Ron Pereira - March 10th, 2009

A person going by the name of “ford” left a very interesting comment to my post about it taking 10,000 hours to become an expert at something. Here was the comment: “The moment one gets into the `expert’ state of mind

Kaizen and the Art of Elephant Eating

By Jon Miller - March 10th, 2009

Do you have an elephant that needs to be eaten? If you did, would you know? There is something called the elephant test which comes from the field of law. It is often used for cases in which something “is hard to describe, but in

"Lean Factories Find It Hard to Cut Jobs"

By Jon Miller - March 9th, 2009

…even in a slump, or so says an article in today’s Wall Street Journal. It’s an unfortunate title with a collection of half-truths about lean manufacturing, some contradictory, that leaves one unsure at the end whethe

Web Check-In: Lean or Not?

By Ron Pereira - March 8th, 2009

The Pereira household has been battling flu like symptoms for over a week now. My kids have all had it and most recently my wife got it. I, knocking on wood, have escaped it so far but I am not getting cocky about it! In any event, at

Ambiguous Visual Controls: When Words Aren’t Necessary

By Jon Miller - March 8th, 2009

Visual controls must by definition be clear indicators of normal versus abnormal, go versus no go, okay versus not okay. The sign above isn’t at all bad compared to other ambiguous visual controls we’ve featured here, here

Lighting a Candle for Energy Sustainability

By Jon Miller - March 6th, 2009

There was a great teaching moment this week. As we were walking around the shop floor at the end of the day, the shift ended and people began streaming out of the factory. Soon the lights began to shut off. We were left alone, in the d

Spreading the Gospel with Web Video

By Ron Pereira - March 5th, 2009

Man, who would have thought a video I shot at around midnight with a crappy digital camera and some shop lights from Home Depot clipped to a step ladder – yes that’s exactly how I did it! – would be watched more than

The Art of Giving Instructions

By Ron Pereira - March 3rd, 2009

So, it would seem that the conversation between cake maker and customer went something like this. Cake Making Employee: Hello, how can I help you? Customer: I would like to order a cake for a going away party this week. Cake Making Emp

What’s All the Fuss About A3 Thinking?

By Jon Miller - March 3rd, 2009

Jim had a good point in his comment: I don’t understand the excitement about this so-called A3 thinking. Root cause analysis has been around for decades, so has five whys (at least since the very early 1980s.) As for hypothesis t

Porque é que esta água fria?

By Jon Miller - March 2nd, 2009

That is how the sun sets over the Amazon in the evening. But today let’s talk about how the water comes out of the shower in the morning, which is to say cold. When this happens one is faced with three choices: wait until the wat

Stop Shining… Clean to Inspect

By Ron Pereira - March 1st, 2009

The third S, in 5S, is commonly referred to as shine. A more accurate translation of the original Japanese word – seisou – is probably scrub or sweep. But shine works as well. Missing the Point But here’s the thing. Most people c

Guest Post: Should You Display Standardized Work Sheets at the Workstation?

By Jon Miller - March 1st, 2009

by Franck Demarest When discussing this subject with many people, I often encounter the dilemma about the location of standardised work sheet meaning either close to the line or in a cupboard in management office. About which standard

10,000 Hours of Practice

By Ron Pereira - February 26th, 2009

10,000 hours. That’s precisely how long you need to practice something before you can even think about calling yourself an expert. Well, at least this is what Malcolm Gladwell claims in his newest book Outliers, which I must say is o

Taiichi Ohno’s Three Lessons for the New Toyota President

By Jon Miller - February 26th, 2009

Yesterday Kevin Meyer provided a useful summary of how Toyota is getting back to basics, as described in the Wall Street Journal article titled “A Scion Drives Toyota Back to Basics”. Here are the key takeaways from both so

You’re Late. What Do you Say?

By Ron Pereira - February 24th, 2009

It’s 7:58 AM and beads of sweat are forming on your forehead. Your pulse rate is increasing as you grip your steering wheel tightly. And to make matters worse… you forgot your mobile phone at home. In 2 minutes you will officially

Drive and Dedication Power the TBP Process

By Jon Miller - February 23rd, 2009

As a companion to the problem solving funnel or the 8 step approach of the problem solving process at Toyota, there is a set of principles that guide thought and action. Together these make up the newly described way of working called

The Complete Meaning of Shitsuke

By Ron Pereira - February 22nd, 2009

There are some Westerners (Americans, Europeans, etc.) who get all bothered when lean folks use too many Japanese terms. So these people go on about how it’s “Policy Deployment” and not “Hoshin Kanri” or it’s “Continuous

TBP: Toyota Business Practice

By Jon Miller - February 22nd, 2009

Are you interested in practical problem-solving and continuous improvement methodologies? In this blog post, we explore the Toyota Business Practice (TBP) and its relationship with PDCA and A3 thinking. We also take a closer look at th

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