Gemba Academy

JIT and Jidoka are Useless…

By Ron Pereira - January 30th, 2008

Yes, the two pillars of the Toyota Production System – JIT and Jidoka – are absolutely worthless… if you don’t respect people. You see, in my opinion, anyone who tries hard enough and gets support from more ex

Breaking Down Barriers to Continuous Flow

By Jon Miller - January 28th, 2008

One way to look at lean is that it’s all about enabling the continuous flow of actions, information, materials, services and cash in such a way that these things generate of goodness, however you may define that. The theory is th

Rope Suppliers

By Ron Pereira - January 28th, 2008

J Thatcher recently asked: Here’s a question: If the student becomes the initiation point for “pull” learning, how does the instructor continue to “push” students beyond what they believed themselves capable? (And yes, I’m

Inspired at NASA

By Ron Pereira - January 27th, 2008

This past weekend my family and I went to Houston to visit some relatives. On Saturday we went to NASA. If you have never been there you need to carve out some time to make this visit. I took quite a few pictures and will try to

Sustainability, the New Buzzword. But Is It Sustainable?

By Jon Miller - January 26th, 2008

Thanks to polar ice melts, $100 per barrel oil prices, and an inevitable generational shift to people who have grown up hearing about environmental destruction arriving in positions to influence opinion, consumption and policy, sustain

101 Kaizen Templates: ECRS Worksheet

By Jon Miller - January 25th, 2008

We often talk about lean management being the elimination of all waste and non-value added. We may call it the pursuit of perfection, of a waste-free process. But what if we can’t eliminate a certain waste from a process? What to

Should we Push or Pull in Schools?

By Ron Pereira - January 24th, 2008

My good friend, and excellent blogger, Mark Graban posted an interesting article related to how a school is using continuous improvement methods to, well, improve things. For those who don’t know, Mark and I live in the same town an

What Can We Learn from Boeing's Lean Supply Chain Stumbles?

By Jon Miller - January 23rd, 2008

Not much more than a decade ago, Boeing went through a hiring binge to ramp up production, fell flat on deliveries and shed many jobs as a result. Gemba’s office is quite near Boeing’s Everett, Washington factory and the fu

Excellence is a Habit

By Ron Pereira - January 23rd, 2008

“We are what we repeatedly do. Excellence, then, is not an act, but habit.” -Aristotle I am doing my best to teach my kiddos about lean and six sigma. Since they are ages 5, 3, and 1 my instructional tactics need to be crea

Textron CEO on State of Six Sigma

By Ron Pereira - January 22nd, 2008

USA Today recently interviewed Lewis Campbell, Textron’s CEO. The questions were mainly centered on Textron’s enterprise wide deployment of Six Sigma. They asked several questions, some of them quite tough. All were answered with,

16 More Ways to See Motion Waste when Standing in the Circle

By Jon Miller - January 21st, 2008

The stand in the circle activity is a great way to train your eyes to see waste on your gemba. Finding 30 small kaizen ideas in 30 minutes, and rapidly implementing at least one of those ideas is a practical and scalable way of teachin

Has Lean or Six Sigma Changed your Life?

By Ron Pereira - January 21st, 2008

Mark Graban just posted an article about LEI’s newest book. Looks to be sort of like the Lean Lexicon but with blog-like quotes. Mark shared one of the excerpts from the book. “Lean should not have ‘changed’

101 Kaizen Templates: Minor Motion Analysis

By Jon Miller - January 19th, 2008

We’re big fans of making significant organization-wide change by involving everyone in small improvement activities every day. This is especially important for sustainability as you progress on your lean journey. As you progress

Learning to Learn

By Ron Pereira - January 17th, 2008

Lean Enterprise Institute has a book called Learning to See. It’s about how to use value stream maps to “see waste” in a new way. It’s a great book and even better book title. Go to Amazon and check it out. But I think an even

Lay First the Foundation of Humility

By Jon Miller - January 17th, 2008

I came across this great quote by St. Augustine. Do you wish to rise? Begin by descending. You plan a tower that will pierce the clouds? Lay first the foundation of humility. These words work on many levels. When corporate board rooms

The Pros and Cons of Model Lines for Lean Implementation

By Jon Miller - January 16th, 2008

In continuous improvement terminology a “model line” is a closely connected series of processes that are the target of focused implementation of lean principles. It derives from the selecting a production line and convertin

Shadows or Reality?

By Ron Pereira - January 14th, 2008

One of my passions in life is to learn. As such, I have begun the year by ditching books about leadership, lean, and six sigma (for now). In their place I have decided to study philosophy which may make you want to yawn… but I woul

101 Kaizen Templates: Safety Calendar

By Jon Miller - January 13th, 2008

Early in the year is a good time to refresh our commitment to health, safety and sustainability of our various enterprises. Despite our best intentions, habits being what they are, these resolutions are too often not so resolute. Unlik

Japan Here I Come!

By Ron Pereira - January 11th, 2008

I am excited to announce that I am headed to see lean manufacturing at its best as I join Gemba Research on their upcoming Japan Kaikaku Experience. We arrive in Japan March 9 and the plans are to visit the following companies during t

Building a Lean Supply Stream

By Ron Pereira - January 10th, 2008

If you happen to live in the Dallas/Fort Worth area or will be in town you may consider attending this conference. I plan to attend so let me know if you will be there so we can say hi! Apologize for sending this out late… bu

101 Kaizen Templates: Stand in the Circle

By Jon Miller - January 9th, 2008

The 60-minute kaizen exercise we call “stand in the circle” originates in the teaching method Taiichi Ohno used. This involved a piece of chalk, a circle drawn on the concrete floor, and a manager left to stand in it for ho

The Highest Form of Human Excellence

By Ron Pereira - January 8th, 2008

“I know you won’t believe me, but the highest form of Human Excellence is to question oneself and others.” -Socrates When someone asks me a question I typically respond with an immediate answer. There are many issues

The Secret Lives of Toyota Term Employees, Episode 5

By Jon Miller - January 7th, 2008

Do you live with the fear that your job may be gone tomorrow? Toyota group company workers do, according to an article titled Growing Reliance on Temps Holds Back Japan’s Rebound in the Wall Street Journal on January 7, 2008. The

That which doesn’t kill us makes us stronger

By Ron Pereira - January 7th, 2008

As a young boy growing up in Ohio I learned to love Ohio State. I was watching them play football before I even knew what football was. It’s hard to explain to most how much I love them. And it’s hard to express how s

101 Kaizen Templates: The Checklist

By Jon Miller - January 6th, 2008

This is the first post in the 101 kaizen templates series. Only 100 more kaizen templates to go. Takt time is 3.5 days per template. I considered planning out and structuring this series but for now we’ll just go with the flow an

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