Gemba Academy

101 Kaizen Templates: Daily Hansei Sheet (Pluses & Deltas)

By Jon Miller - February 20th, 2008

Ron Pereira wrote an article titled “How not to screw up pluses and deltas”. It gives useful tips on how to properly review at the end of a day of class room training or a shop floor kaizen. The pluses and deltas activity i

Clean up, Guide to Lean, and more

By Ron Pereira - February 19th, 2008

Things have been pretty crazy around here the last few days. Switching over to this new website was definitely worth it… but not without it’s share of work. Clean Up When you switch to a completely new design like this ce

Is Lean a Superstition?

By Jon Miller - February 18th, 2008

The Training Within Industry blog took up the debate on “Is lean a religion?” a few weeks ago. The article points out that when done right, lean is more of a philosophy that guides how you do thing and how you lead people.

One Piece Flow versus Mass Production

By Ron Pereira - February 18th, 2008

Update on Nov 6, 2020: The original version of the video is no longer available. But I did want to add a note that the reaction to this original article was one of the main reasons Gemba Academy exists today. I have left the original c

What is RSS?

By Ron Pereira - February 17th, 2008

I’ve been asked by a few folks what the funny looking blue icon on my front page was all about. So, let’s take a break from lean and six sigma and talk about the wonders of RSS. The Good Old Days In the old days when we wanted

101 Kaizen Templates: Motion Economy Chart

By Jon Miller - February 16th, 2008

One of the toughest things that a kaizen consultant has to do is to tear down the results of past kaizens. This is hard because people develop a sense of ownership of the status quo they helped to build. Even if the status is not good,

The Seven Steps to Zero Thinking

By Jon Miller - February 13th, 2008

There are many misguided ways to explain or to think of lean management. We’ve discussed some of these in the 10 common misconceptions of lean manufacturing previously. It may not be complete but it is correct to think of lean as

Kudos to American Airlines and DFW International Airport

By Ron Pereira - February 13th, 2008

I just had the best experience here at the DFW International airport. I pulled up to the drop-off zone, kissed my wife and kids good-bye, grabbed my bags, headed to the Executive Platinum check in line (one of the benefits of frequen

101 Kaizen Templates: Spaghetti Diagram

By Jon Miller - February 12th, 2008

The spaghetti diagram needs very little introduction. It’s so named because the lines movement drawn on this diagram resemble a pile of tangled noodles. It’s a movement path diagram by a more appetizing name. Seeing Wasted

How to Create a Product Quantity / Product Routing Matrix

By Ron Pereira - February 12th, 2008

In part 1 of our series on value stream mapping (VSM) we were introduced to what a value stream is. We also discussed the roadmap I personally use when working with this powerful tool. In this installment, we’ll take a deeper dive in

Kaizen Your Life with the Ten Lessons for Good Health

By Jon Miller - February 11th, 2008

These ten lessons for good health (健康十訓) are glazed onto my teacup. Reading these while sipping green tea has helped me survive over the years. Lean healthcare professionals take particular note: prevention trumps correction ev

Value Stream Mapping Overview

By Ron Pereira - February 8th, 2008

One of, if not the single most powerful lean tool available to us is value stream mapping (VSM). The reason it’s so powerful is because of its relevancy. You see, it doesn’t matter if you are an accountant who sits behind a

101 Kaizen Templates: Changeover Analysis

By Jon Miller - February 7th, 2008

There are many common non-lean behaviors such as local optimization, batch work, and building up inventory. Creating WIP lengthens cycle time, worsens quality, builds up barriers between processes and people contributes to late deliver

Long Live the King (Cash)

By Ron Pereira - February 7th, 2008

If you are involved with a for-profit business in any way please remember one thing – cash is king. Of course respecting people is absolutely critical. But cash pays the bills. It buys things. It pays salaries. So without money in

Management by Kaizen Events

By Jon Miller - February 6th, 2008

Mark Graban made the point today in the Lean Blog that kaizen events are not enough. He agrees with another lean healthcare article that by themselves, the rapid improvement events of 3 to 5 days in duration are not sufficient to achie

Schofield Media Group Announces Acquisition of iSixSigma

By Ron Pereira - February 6th, 2008

Big news yesterday from Michael Cyger, owner of the extremely popular iSixSigma brand. I am pleased and excited to announce that CTQ Media, owner of the publishing brands including iSixSigma, Real Innovation, BPM Enterprise and Sourcin

The Never Ending Pursuit of Wisdom

By Ron Pereira - February 5th, 2008

Let no one deceive himself. If any one among you considers himself wise in this age, let him become a fool so as to become wise (1 Cor 3:18). Wisdom is a mysterious thing and something, I contend, worth our full attention. You see, I

101 Kaizen Templates: Takt Time Calculator

By Jon Miller - February 4th, 2008

A reader pointed out that the takt time for posting the 101 kaizen template has exceeded. It is true that we have not been hitting a consistent 1 template per 3.5 days. To meet our goal for 101 of these by the end of 2008 we will need

Exploring the “Respect for People” Principle of the Toyota Way

By Jon Miller - February 3rd, 2008

Author, Professor and lean thinker Bob Emiliani has made another important contribution with his new book Practical Lean Leadership. I had the pleasure of reviewing and giving editorial input on this fine book and would recommend it fo

Just Do It

By Ron Pereira - February 2nd, 2008

“Talk doesn’t cook rice.” -Chinese Proverb While planning, checking, and acting/adjusting are of course crucial elements of the PDCA cycle I sometimes feel as though the “do” element is under-utilized. In a similar way,

The Secret Lives of Toyota Term Employees, Episode 6

By Jon Miller - January 31st, 2008

Tomorrow is Creative Idea Suggestion Submission Day What happens after a term employee at Toyota becomes a regular employee? Is this the happy ending when the assembly line workers finally feel the warm embrace of President Watanabe? D

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

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