Gemba Academy

Zero Equals Seven in the Kaizen Mind

By Jon Miller - May 15th, 2007

Taiichi Ohno taught us that even when we think “there is no waste here” you can find at least 7 types of waste. He was known to carry a piece of chalk around and draw circles around managers who could not see these wastes.

Riding a Bike

By Ron Pereira - May 14th, 2007

This weekend my 4 year old daughter learned to ride her bike without training wheels. She has been after me for quite awhile to let her have a shot but I have been hesitant. I just didn’t think she was ready. But after she saw her 5

Misconceptions

By Ron Pereira - May 13th, 2007

The first several chapters of Taiichi Ohno’s Workplace Management spend a lot of time discussing misconceptions. Ohno said: “Very often after we try we find that the results are completely opposite of what we expected, and this is

To KPO or Not to KPO?

By Jon Miller - May 13th, 2007

Here is a bit of heresy that has been rolling around my brain lately: having a KPO / Six Sigma Competency Center / Office of Operational Excellence / Continuous Improvement Office hurts rather than helps a Lean effort. Best case, these

Waiting in US Immigrations Line

By Ron Pereira - May 12th, 2007

I have really enjoyed learning more about the Queuing Theory from our friend, Peter Abilla, over at the excellent shmula blog. Peter’s most recent post is about the Queuing Psychology at the Gus Pump. Yesterday I traveled home from E

5S Challenge: Which S Is Most Difficult and Why?

By Jon Miller - May 12th, 2007

“Which of the 5S is most difficult?” I received this question during a class I was teaching recently. I’ve never been asked this before. People often say “self-discipline is the most difficult” or “s

Taguchi L18 DOE

By Ron Pereira - May 9th, 2007

Design of Experiments (DOE) are perhaps the single most powerful tool I have found to screen, characterize, and optimize a process. For an introduction to what DOE’s are please read this post. Taguchi L18 Tonight I want to focus in a

Will the Real TPS Sensei Please Stand Up?

By Jon Miller - May 9th, 2007

Tetsuo Hoshino is the Chairman of Gifu Auto Body Industry, a Toyota Group company. He was a student of Taiichi Ohno. Since 1990 he has taught the Toyota Production System to 20,000 senior officials in large Korean companies. Hoshino re

Repetitions versus Replications

By Ron Pereira - May 8th, 2007

Many Lean & Six Sigma practitioners struggle to differentiate between a repetition and replication. Normally this confusion arises when dealing with Design of Experiments (DOE). Let’s use an example to explain the difference. Pai

Seven Ideas Towards a Healing Workplace

By Jon Miller - May 8th, 2007

The entry last week on Standards, Abnormality and the Ideal seems to have struck a chord with folks. I’ve been thinking further about the idea of negative accidents or negative safety incidents and it is quite sound in theory and

Could Work Kill You?

By Ron Pereira - May 8th, 2007

I am a frequent flier and thus read lots of airplane magazines. One of the better mags of the sky is American Way from American Airlines. The May issue is about all things Asia. There are several good articles but the one that really c

First Impression of Workplace Management

By Ron Pereira - May 7th, 2007

I have now read Taiichi Ohno’s Workplace Management which was recently translated by Gemba Press. I have already started reading it a second time as I know I will gain an enormous amount reading it again (and maybe a third time). I w

Hangin’ with Taiichi – Update

By Ron Pereira - May 6th, 2007

As I explained a few nights ago I received my copy of “Workplace Management” by Taiichi Ohno. When I first looked at the book I was a bit surprised at how small the book looked. Normally when I see a 100 something page book

Five Lean Ideas to Reduce Hotel Energy Waste

By Jon Miller - May 6th, 2007

Five small things this European hotel chain is doing to reduce energy waste: 1. The lights, television, etc. turn off when you take key card and leave the room 2. The lights in the elevator turn on only when the doors open and you walk

Outsourcing versus Offshoring

By Ron Pereira - May 6th, 2007

It seems like every time I turn around there is a new survey. One says Lean rocks, one says almost everyone that tries Lean fails, and one says Dilbert ruined Six Sigma. OK, this last one is stretching it a bit. Maybe. Well just today

Saudi Arabia meets Six Sigma

By Ron Pereira - May 5th, 2007

A series of ‘Six Sigma Foundation Courses’ are going to take place during May 2007 in different cities of Saudi Arabia. Link to article.

100% Dissatisfaction is Our Goal

By Jon Miller - May 4th, 2007

A May 4, 2007 USA Today article titled Toyota’s success pleases proponents of ‘lean’ looks at the story of Toyota surpassing GM by volume of cars sold and from the angle that the Lean consulting industry benefits. The

Standards, Abnormality and the Ideal

By Jon Miller - May 3rd, 2007

The topic of warusa kagen led to some interesting further thought. The following statements are all true: 1. When work is performed in the absence of a standard, this is an abnormality 2. When standards exist but are not being followed

Hangin’ with Taiichi

By Ron Pereira - May 3rd, 2007

Let me set the scene of this momentous moment.My wife had already left for her Bible study. I had two kids in the tub (2 year old and 8 month) and my 4 year old was doing something bad… I am sure of it but can’t prove it si

Wanna Be Lean? Buy Some Carousels.

By Ron Pereira - May 3rd, 2007

I recently came across an article that irritated me. The gist of its message is that once all the “easy stuff” with Lean is taken care of… you know like respecting people, improving quality, and pulling material through t

Warusa Kagen is a Revolution of Awareness

By Jon Miller - May 2nd, 2007

There is a Japanese term that I like but is sadly not used as often as others in the Lean community, and may be indicative of a lack of focus in this key area of awareness. It is warusa kagen (悪さかげん) and means “conditio

Repent, I mean Hansei!

By Ron Pereira - May 2nd, 2007

I never seem to stop learning from my friend Jon Miller. I wanted to write a post about hansei and thus decided to dig around to see what other bloggers had to say on the topic. I typed hansei into Google and mid way through the firs

100th Post!

By Ron Pereira - May 1st, 2007

Tonight was my 100th post since starting LSS Academy in January of this year. So as I sip on some cheap Sutter Home White Zinfandel wine (California 2003) and reflect on the past few months I would just like to say thanks to all of you

Dumbing Down Six Sigma

By Ron Pereira - April 30th, 2007

I recently came across an interesting article written by Mark Kiemele, co-founder and president of Air Academy Associates. In the article Mr. Kiemele discusses how Six Sigma could die a slow death or remain around for many years to com

We Are Now Shipping Taiichi Ohno’s Workplace Management

By Jon Miller - April 30th, 2007

Sweet relief, the books have arrived. Thanks for your patience. We’ve set up a flow line to pack and ship, paced at about 90 seconds per order. Now don’t everybody order at once. We value heijunka around here.

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