Category Archives: Manufacturing

IIPP Innovative Techniques Get Employees Attention for Safety

Part II of Injury and Illness Prevention Programs (IIPP), following announcement of OSHA’s pending standard.  

Safety is not the most exciting subject to speak about that will hold an audience’s attention. But to get your employees’ attention, take a look at these innovative techniques for safety program implementation.

You can think of injecting the element of surprise or unexpected humor to help deliver the message. These persuasive examples will illustrate how to take proactive steps for safety in your workplace.

Example 1 – Don’t Walk on By

The Safety music video, Don’t Walk on By produced by Nick James Productions is cleverly done, showing how easily we get accustomed to our surroundings. Consequently, we start overlooking important safety clues that could prevent serious injuries.

How can you utilize the Don’t Walk on By theme?

  • Add your spin on the theme, using a statistic of workplace injuries and illnesses, as well as costs associated with people not doing anything about it (walking on by).
  • Segue into performing your safety audit.
  • Demonstrate how your organization protects employees from workplace injuries and illnesses as well as saves costs through a workplace safety program.

Example 2 – Horror Movies: Workplace Safety Videos Pack a Punch

The recent EHStoday article, titled Horror Movies: Workplace Safety Videos That Pack a Punch consists of a set of impactful commercials produced by the Ontario Worker Safety and Insurance Board called Prevent It.

These short and brutally honest vignettes may be seen as disturbing by some, because of the dramatic way in which accidents are depicted. In a split second an employee’s life can be turned upside down.

How can you utilize this theme?

  • Always be on guard to potential hazards in the workplace and at home. The point is made that “there really are no accidents.”
  • Every accident can be prevented if the employee (or employer) had done something different.

QMA will address your specific injury prevention training and consulting needs, whether you are a large or small employer. Together, we will develop a strategy and a program that fits your industry and organization. For a free consultation, please complete the contact form and we will contact you.

Zippy is Back!

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In case you missed us last time – check out our introductory video of the Zippy Car Workshop!

Public Workshop 

This dynamic four hour workshop enables participants to learn the basic principles of Lean Manufacturing in a no-risk environment. Principles are taught in the classroom and then practiced in a hands-on factory simulation.

In three successive factory simulation rounds the participants convert a traditional factory to a Lean factory environment. Facilitators track the quality and financial metrics from round to round to show the benefits to be derived from a Lean Transformation.

The Lean principles are explained so that its benefits can also be applied to office, service and other non-manufacturing environments.

For a more detailed description you can visit our events page  or watch the brief introductory video.

In-House Workshop

Zippy is available for in-house delivery at your site. For a quote, email Enrique Bekerman, emb109@aol.com.

Learning Lean by Live Simulations

Why bother with the extra expense of a Lean live factory or office simulation?

Live factory simulations have been used  for the last several decades to demonstrate the Lean concepts.  Electronics, clocks, cars, toys, boats, airplanes, electrical connectors,  pens, flashlights have all been popular.  Office simulations to eliminate waste in paperwork/information have also been used. Materials used range from actual products (pens, switches) to more whimsical demonstrations  (Lego assemblies, wooden toys, paper airplanes).

The idea behind all these simulations is to combine classroom learning, through lectures or Power Point presentations, with an actual demonstration of the Lean concepts.  Typically, the workshops are broken into several sections or rounds to represent shifts or days at an assembly operation.

The first round starts  by intentionally demonstrating some of the wastes commonly found in a traditional manufacturing environment.  These inefficiencies are used as talking points for the classroom session.  During the classroom sessions the Lean principles are gradually introduced and practiced during a simulation round.  Quality rejects, amount of product shipped, on-time delivery, and profit/loss are tracked and reviewed after each round.  Subsequent rounds gradually introduce the Lean tools and concepts until the final round representing a Lean Enterprise.

The benefits of Lean including customer satisfaction, waste elimination are demonstrated physically and financially in a way that can be easily understood and applied.  A good facilitator will encourage the students to make the connection between the simulation exercise and their workplace environment.  The workshops are typically presented in skit form to add some levity to the experience.

Because a Lean transformation involves a cultural change, it is essential that everyone in the organization participate in the simulations.  Teamwork and the need for Continuous Improvement are emphasized in the classroom and simulation exercise.

I have participated and facilitated many of these workshops.  I have also, at the client’s request limited the introduction to to Lean to a one or two hour classroom presentation.  In my experience, the latter do not generate the same level of  learning or enthusiasm as in the simulation workshops.  The hands-on experience obtained in the simulation, the facilitator’s ability to relate the simulation to the “real world” experience and the round-to-round factual comparison of the benefits of Lean, in my opinion,  make  simulations a superior method of  preparing an organization for a successful Lean transformation.

Have you had experience in a Lean simulation?  Do you think it is worth the extra time and investment?

It should be noted that workshops typically take a full day. QMA as developed the Zippy Toy Car simulation, a dynamic 4 hour workshop that  in 3 rounds covers the  most important concepts covered in the longer workshops. It is far less disruptive and cost effective. It is designed for in-house delivery, but a Public Workshop is offered periodically.

Enrique Bekerman

 

 

How to Start a Real World Lean Transformation by Live Simulation

 

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Visions of reducing inefficiencies for real-world Lean transformation in manufacturing, distribution, and supply chain operations are only the tip of the iceberg.   Imagine what a live workplace simulation workshop can do for your organization.

A couple of questions are often asked: “Why does anyone need Lean?” and “Would the time and expense of a live simulation workshop be justified?”

Let me answer this first question. If you’re not familiar, Lean is a continuous improvement initiative focused on providing customer value and eliminating waste from processes. The end result is a streamlined operation  able to deliver higher quality products on-time while using fewer resources.  For an explanation of Lean basics you may refer to an earlier blog article .

A live factory simulation workshop is a hands-on technique used for more than twenty years to demonstrate basic Lean concepts. The simulation mode brings in a fictitious operation to serve as a learning tool.  Simulation exercises are conducted to demonstrate different types of waste, and their elimination, as well as relate the techniques learned to “real world” scenarios.

The format of a simulation workshop is divided into several sections or rounds to represent each of the shifts (or days) of the fictitious production facility. Participants are part of the process – through every wheel, screw, and nut assembly. Much like a sports game that excites and draws everyone together to win, Lean simulation workshops have this same effect.

First round starts by intentionally demonstrating the chaos and waste commonly found in a traditional manufacturing environment. Lean principles are gradually introduced and practiced during the subsequent simulation rounds. Discussions open up to talk about what works well and what waste may be eliminated from the process.

Quality rejects, inventories, product quantities shipped, on-time delivery, and profit/loss are tracked and reviewed after each round, so that the effect of waste elimination is clearly identified and quantified.  The simulation continues to introduce the Lean tools and concepts during each round until the final round represents a Lean Enterprise.

At this point, the total benefit of the Transformation can be assessed.  In addition to improved customer satisfaction resulting from product quality and on-time delivery, other physical and financial benefits are demonstrated.  A Lean transformation involves cultural change, and therefore, essentially everyone in the organization should be part of the simulation exercises. Teamwork and the desire for continuous improvement are emphasized throughout the workshop.

Simulation materials may range from actual products like pens and switches to more whimsical demonstrations using Lego assemblies, wooden toys, and paper airplanes. The goal is still the same: eliminating waste. In fact, office simulations have, in a similar way, focused on the elimination of  paperwork and information capture not integral to business objectives.

One of the most difficult choices people have to make is to commit to starting this journey to implement Lean practices. Often the sentiment is that a simulation takes too much time.  In particular, one business owner recently told me “we don’t have the time to stop production to do that kind of training.”

Is there ever ‘the right time’? Most business people would suggest, now, more than ever, is the right time. To prove this point, a Lean transformation would realistically open up opportunities for business, improve the bottom line, and conserve time and expense. That is exactly what happens in a successful Lean transformation. The simulation workshop has become a necessary first step for a successful implementation.

The QMA network of quality experts offers workshops and facilitation to guide organizations on their Lean journey. We don’t claim to be visionaries or missionaries, just that we’re able to demonstrate the most cost effective ways to build more value into the business.

In our experience facilitating Lean transformations, a live simulation provides a higher level of understanding and fully engages employees in accomplishing these business goals through a successful Lean transformation.

The hands-on experience, combined with our in-depth Lean expertise and guidance, enables participants to relate their own “real-world” experience. And the round-to-round factual comparison of Lean practices and benefits, in my opinion, make simulations a superior method of preparing an organization for a successful Lean transformation.

One further note: Workshops of this kind would typically take a full day.

QMA has developed the “Zippy Toy Car” Simulation (another way to say we get it done quickly), a dynamic four-hour workshop of  three rounds that covers the most important concepts as compared to longer workshops.

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The Lean concepts you learn can be literally taken back to your workplace and practiced the same day. The shorter and dynamic format maintains a high level of energy while reducing the investment of time.

Our popular Lean Office simulation workshop takes place at the “Department of Approvals”, a simulated service organization workshop, participants progressively implement Lean tools to experience a transition from a traditional office setting to an efficient Lean service environment. Participants continuously track progress of improvements by collecting data in a report card and monitoring performance measures through each simulation. The workshop leads management and workforce teams through the application and use of Lean tools in making immediate process improvements.

Our training is designed for in-house delivery, but is periodically offered as a public workshop.  Our next workshop,co-sponsored by ASQ South Florida, is scheduled for April 20, 2012.  See our Events page for more details.

Have you experienced a Lean simulation?  Do you think it is worth the four hour investment and expense?

 

Developing a Listening Culture

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In a previous post Leadership and a Trusting Culture   I talked about the importance of developing trust as a critical component of  managing change in any organization.

To build trust, leaders must first develop listening skills.

Team members must know that their ideas will be heard and given proper consideration. The synergies to be derived from team participation will never be realized if team members don’t trust that their leadership will listen and have a capacity to understand them.

Well intentioned leaders often “kill” ideas without even realizing that they are doing it. A large number of phrases have crept into our daily speech that result in immediate freezing of the desire to openly share ideas.  “We have tried that before”, ” that will never work”  are some examples of  idea killing phrases that will halt any creative cooperation. Being careful  to refrain from providing “knee jerk” negative feedback is an important skill to be acquired by all leaders.

It is a well established method in all types of brainstorming exercises to withhold criticism while ideas are being gathered.  The absence of criticism provides an atmosphere where creativity is uninhibited.  Once all ideas are vented, the leader and the team may engage in the critical evaluation of the benefits, costs, and general practicality of each solution to the problem at hand.

The “wild and crazy” ideas that appear impractical at first, often become the real problem solvers.  If  team members are free to think and express themselves they can often put a different “spin” on an impractical idea that overcomes the initial objections.  One idea may be the initial spark of creativity that can be used as a “springboard” by other team members.

When a leader criticizes prematurely, or places too many limits on the types of ideas that are welcomed, the results are predictably unproductive.  In a recent Dilbert comic strip, Scott Adams makes this point.

Tom Feltenstein  offers a hilarious and powerful video, titled “99 Idea Killers.”

Paul Williams advises teams to “pause before you pounce” on an idea.  He has developed  “Idea Killer Bingo Card” to help teams recognize their own use of reactive negative feedback.

I heard one of  QMA clients express disappointment with the results of their “suggestion box” recommendations.  In facilitating some of their team efforts it became evident to us that leaders, at all levels, were quick to criticize the ideas of others and find reasons why the solutions wouldn’t work.  They often assumed they knew the answers to the problems.

After privately confronting them with their negative attitudes towards the ideas of others, they made genuine efforts to improve the way they interacted with team members.  It turned out that many of their inefficiencies were easily eliminated once team members trusted their leaders to listen to them and became fully engaged in the organization’s continual improvement efforts.

What is the worst idea killing criticism you’ve witnessed?  Do you have a special technique to deal with negativity of  “idea killers”?  Please share your comments below.

Lean: Is It All or Nothing?

Lean: Is It All or Nothing? – Manufacturing Executive Community- Question posted originally on: http://www.manufacturing-executive.com/message/2637

Enrique’s answer:

A company can often obtain small gains by utilizing the Lean tools.  For instance, using 5S to organize the shop floor results in immediate gains in productivity and accident prevention.  However, sustainability of the improvements depends on the last two steps “standardize” and “sustain”. This is where most organizations fail and where the development of a Lean culture is necessary.

The development of a Lean culture takes time, as Matt mentioned above.  As people start seeing the benefits of Lean, they will start getting involved in improvement efforts.  Lean is all about incremental improvements that add up over time.  If large gains are obtained initially, that is icing on the cake.

The emphasis should be on Continuous Improvement and waste elimination, not on cost savings (these will come soon enough).  Training, education and empowerment at all levels are also essential to developing a culture where waste elimination is an integral part of the organization.

Lean ISO and the Eighth Waste

The elimination of waste is the main focus of Lean Manufacturing.  In recent years, many organizations have incorporated the concept of the “eighth waste” in their implementation of Lean Manufacturing.  Many early sources spoke about the Seven Wastes that are found in most processes:

  • Overproducing
  • Transporting
  • Waiting
  • Inappropriate processing
  • Building unnecessary inventories
  • Conducting unnecessary movements
  • Defects and errors

Lean practitioners have come to recognize that elimination of these seven wastes is highly dependent on getting people involved in the Improvement process.  This failure to fully utilize the workforce talents and fully engage employees is now considered the most significant waste of all and is referred to as the eighth waste.

These wastes are symptoms of the underlying root cause for the real problems. For instance, excess inventories may be an indication of unbalanced workloads, machine breakdowns, misunderstood customer requirements, and unreliable suppliers.

Being on the lookout for the evidence of waste provides a starting point for the investigation of the root causes and for finding solutions to the problems.  Employees are not only closer to the symptoms, but also closer to the root causes of the problems.

In a previous article, I explained the compatibility of ISO 9001:2008 and Lean Manufacturing.  ISO 9001:2008 specifies that the organization must disseminate its’ Quality Policy and Objectives so that all employees understand them and how their jobs contribute to them. It also specifies that the organization must be engaged in the continual improvement of its Quality Management System.

The eighth waste can be described as “underutilized minds.”  Although ISO has some built-in requirements for improvement such as internal audits, corrective and prevention action systems, it does not prescribe how employees, in general, should be involved in the continual improvement of the organization.

To address the eighth waste, organizations desiring to institute a Lean ISO system need to:

  • Train employees early in the process on the Quality Policy and Objectives  so that they begin to understand their roles in the process.
  • Engage employees in the documentation process including involvement in writing the initial drafts of procedures or work instructions.
  • Select and train employees as Internal Auditors so that they learn about other areas within the company when participating in audits.
  • Involve employees in Internal Audits as both Auditors and Auditees.
  • Engage employees in workspace organization and standardization (5S) and in improvement events such as Value Stream Mapping and Kaizen activities.
  • Train employees in root cause analysis and basic problem solving techniques so that they can assist in maintaining the Corrective and Preventive Action Systems (CAPA).
  • Develop workplace organization score cards and train your Internal Auditors in their use.

These actions will significantly reduce the eighth waste in the organization by engaging the workforce in the Continual Improvement process.

Manufacturing and Innovation

There is no doubt that the key to long-term success in manufacturing is innovation in every facet of the business, from developing unique products, like the iPod, to finding new ways of getting products into people hands, like Amazon.com.

Pharmaceutical and consumer products companies, among others, have historically shifted their mature products overseas, while maintaining at least some of their domestic operations for the development and early production of new products and line extensions. US based manufacturing has heavily relied on the rate of innovation of the organization. This trend continues and is the key to our manufacturing base.

High margin products, such as medical devices, are less sensitive to relative production costs as long as they have a unique product. Even in those cases, as volume increases the financial pressures to migrate production to locations with lower labor costs also increase. Such high margin industries continue to be significant to our manufacturing base.

In South Florida, manufacturing is not considered by local governments as a target sector for expansion. No effort is made to attract new manufacturing plants. Municipalities and county governments are more interested in attracting and retaining “cleaner” industries, such as, tourism and entertainment. On a national scale, manufacturing has not been recognized as the significant sector that it is.

The role of government at every level is to provide the conditions needed for innovative manufacturing to flourish and to prevent other countries from establishing barriers to the entry of our products while our doors are wide open to the world’s products.

To summarize, I agree that innovation is the key to continued success combined with forward thinking leadership at every level of government.