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The Manufacturing Leadership Center explores various aspects of manufacturing excellence delivered and moderated by renowned lean expert Bill Waddell.

We are bringing together the best lean thinkers, the most credible experts and manufacturing thought leaders who are defining the future. The content includes facts, lessons, opinions and news on manufacturing excellence. The format ranges from blog posts and white papers to videos, presentations and graphics. In order to assure our objectivity, we do not accept advertising, and link only to the sites where you can get more information concerning our content providers. Lastly, we are always looking for emerging lean thinkers who may not be well known, but have something important to contribute to the body of knowledge, and may well be the thought leaders of the future. Anyone interested is encouraged to submit their content for review.

NAM, Paychecks and CAT

May 17, 2013 by Bill Waddell 1 Comment

I have been flipping back and forth about whether the theme of this post should be the National Association of Manufacturers (NAM) going completely over to the dark side, or about the two polar opposite theories of compensating people.  The prime evidence for the first theme and the poster boy for the second are embodied in one person – Caterpillar CEO Doug Oberhelman.

To put this guy in proper perspective, he worked as a repo man in his younger days, in his words “You knock on the door, and you tell somebody you’re gonna take their car away—and usually they’re down on their luck, and their car is the last thing they have.”  According to Oberhelman, “It was a fabulous experience.”  Not a sobering experience, not an enlightening experience, not one that led him to be thankful that there but for the grace of God go he, not even a tough-job-but-someone-has-to-do-it experience but “a fabulous experience” to take away “the last thing they have”.

At any rate, Oberhelman is now the chairman of NAM – speaking for all of American manufacturing, or so they would have you think.  His philosophy: “I always try to communicate to our people that we can never make enough money.  We can never make enough profit.”  I’ll bet every Cat employee around the world can’t wait to get to work in the morning to help him with that inspirational goal.  While every manufacturer supports his advocacy for lower taxes and an end to the regulatory deluge, the truly domestic ones part company with NAM over trade.

For years NAM has been the center of a battleground between those who wanted to use it as a champion for American manufacturing, and the multi-nationals who wanted to use it as a lobbying tool to dupe Congress into thinking that opening the doors from the likes of China, Cambodia and Bangladesh (where they operate) was somehow in the best interests of American manufacturing.  In Oberhelman, the MN’s won and there is little NAM has in common with the interests of the thousands of small and mid-sized American manufacturers who operate domestically (and do the bulk of the hiring in the USA).

But it is in the compensation area that Cat and Oberhelman really diverge from the principles of lean and the values of most privately held, domestic manufacturers.  Not too surprising, Oberhelman, after moving on from his “fabulous experience” in the repo industry, he rose through the accounting ranks to the top of Cat.  Along the way he bought in completely to the notion that people are commodities, to be valued at replacement cost.  A Cat worker should be paid for the amount it would take to hire someone to take his place, and not a nickel more.

That approch, usually centered around HR driven wage surveys that try to figure out just what someone with your skills gets paid in the community – then assuming that you should be paid that amount, regardless of much of anything else – misses a fundamental point.  It is akin to valuing the family scrapbook lost in a fire at the depreciated cost of the book and the money paid to develop the photos in it. Any value that cannot be clearly and easily quantified in dollars and cents doesn’t exist. It doesn’t take things like attitude, work ethic, loyalty, experience and such into account.  Again, it assumes that people are commodities and those intangibles have no value.

Even moderately enlightened companies are moving more and more to compensation schemes that share the wealth –base pay plus an inventive based on profits, cash flow, delivery, quality and safety.  They acknowledge that obvious truth that good results in those areas are created by everyone involved – all of the stakeholders.  The Oberhelman philosophy – the opposite – is that profits are driven by guys like him; and that any collection of warm bodies willing to show up at Cat in the morning will be equally effective tools for him to use to execute management’s brilliant schemes and make their billion plus profits happen.  Therefore, those profits are for the stockholders alone – with a liberal commission due to the likes of him for being the genius who made it happen.

Don’t get me wrong.  I am all for profits – the more the better – but they are created by and should be shared by all of the stakeholders.  And I have no sympathy for the unions at Cat who are complaining so long and loud.  Unions are 100% non-value adding waste and a barrier making effective inter-company communications and teamwork impossible.  That said, if I worked for this guy at Cat, and understood just how he thinks, I would be in full solidarity with my union brothers.

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Filed Under: Accounting & Finance

Eco-Self Deception

May 15, 2013 by Bill Waddell 2 Comments

Massive McMuffinThis is the Massive McMuffin – bacon and sausage, egg, cheese … the works.  Start the day off with one of these and you’re better than halfway to your daily fat intake before you even get out of the starting gate in the morning. You have to go to New Zealand to get one.  Imagine someone who eats these every day, but brags ad nauseum about their healthy lifestyle because they wash it down with a Diet Coke, rather than the fully sugar-loaded version.

How you would react to those boasts is about the same way we should all react to the ludicrous claims to environmental improvement from the likes of H&M and Walmart.

 

The environmental impact of a company is most accurately measured by the length of its supply chain.

H&M manufacturers in some of the least environmentally regulated places on the planet and Walmart buyers probably have to get within a quarter mile of their supplier factories to even see them through the smoke and pollution in some of the places they buy (and pretend that avoiding the cost of environmental regulations is not part of their reason for being in the sort of places Dante waxed eloquently of).  Entire steel mills are apt to be dedicated to cranking out the containers and container ships needed to keep these guys going.  Those ships meet up with entire fleets of trucks and trains pulled by locomotives with massive diesel engines in the LA basin where on most mornings one can stand on a neighboring mountain top and see … nothing.  It is impossible to calculate the resources and energy it took to build their warehouses, and Walmart’s stores.  Fleets of trucks connect those resource wasting distribution centers with resource wasting stores.

But …. H&M has made “Conscious Commitments” to things like using organic cotton and using less water per yard of denim than anyone else.  Walmart says that, “Environmental sustainability has become an essential ingredient to doing business responsibly and successfully”.  They even have a ‘Green Room’ where you can chat with them about their carbon footprint.  Right.  And I am qualified to lecture on health because I did even better than Diet Coke – I washed that massive McMuffin in the photo down with orange juice.

Real Eco-friendliness comes from the likes of West Paw Design – an pet products manufacturer that not only manufactures in the USA with recycled material, but sells on line without all of the containers, DC’s and brick and mortar waste.

Environmental commitment means regional sourcing, and selling only needed quantities through channels with the fewest non-value adding steps.  If a company opts for long inbound supply chains, resulting in massive consumption of fossil fuels and warehouses full of racks and forklifts, that is their prerogative, of course, but they shouldn’t kid themselves and the rest of the world by patting themselves on the back for their environmental concern because they recycle their pallets.

Put another way – putting solar panels on a distribution center is nothing more than putting perfume on a pig.

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Filed Under: Strategy, Supply Chain

On Reluctance to Change

May 14, 2013 by Bill Waddell 1 Comment

A professor from London by the name of Julian Birkinshaw penned a pretty good article for CNN called “Why Corporate Giants Fail to Change”, listing …

  • Ossified management processes
  • Old and narrow metrics
  • A disenfranchised front line
  • Lack of diversity
  • Intolerance of failure

… as the key reasons. Seems like a pretty good list.  The short term perspective also strikes me as a major contributor. While a lot has been made (with quite a bit of merit) over the influence of reporting quarterly earnings to Wall Street on the short term priority, the risk aversion he describes under “Intolerance of Failure” also plays a part.  I see it as a bit like the 40 year old guy who is overweight, drinks or smokes, doesn’t get much exercise.  He knows he has to change because those things will kill him – but he also knows they probably won’t kill him tomorrow.  So he rationalizes putting the change off, far too often until it is too late.

In reading the article I began to think about the small and medium sized businesses who are often just as reluctant to change, and if the same factors applied to explain the reluctance.  I don’t think the “ossified management processes”, “intolerance of failure” or a “disenfranchised front line” are nearly as strong in the smaller organizations.  If anything, lack of management processes is a problem – doing too much and making too many decisions by the seat of the pants with no repeatable, consistent way of running the business.  And while it is not always true, smaller companies are closer to the front lines and more forgiving.

Technical Cultural GridI have come to believe that the biggest problem with many smaller businesses when it comes to transforming to a higher level is quite often a lack of basic technical competence.  They are simply lacking in fundamental skills… and they don’t know what they don’t know.  I have shown the skills versus culture grid in the past; and effective companies promote and support people who fall in quadrant B – people equally high in terms of their technical knowledge and their commitment to a holistic culture of creating and nurturing value for all stakeholders.

The problem with the big guys is their imbalance toward technical competence, and too little regard for culture.  They hire and promote people based too much on academic credentials, or the measurable success in past jobs without consideration for what kind of people they are or how they got those results.

Small companies err too far the other way. They place great value on local candidates who they know and who fit in well with the culture; often sacrificing too much technical competence.  They perpetuate the way things have always been done from a purely technical standpoint.  It is not at all unusual to come across companies with absolutely no formal supply chain or process engineering function – those are simply part time concerns fro production managers; or to find companies with no marketing or product management function at all.  Those are things sales people do as a sideline.

Of course the problem with many smaller, privately held companies stems from the top.  As a VP at one quite successful family owned business told me, at any other company the CEO would be a mid-level manager.  The CEO is very hard working and quite capable in some areas, but he simply doesn’t have the breadth of knowledge and experience one needs from a CEO.  In is case he is fairly aware of his shortcomings and does a pretty good job of deferring to subordinates in the areas in which his knowledge is lacking, but he doesn’t have the knowledge to push those subordinates when they are reluctant to change in directions necessary to support a lean transformation.  In the worst smaller organizations that leader doesn’t even have the humility to acknowledge the knowledge gaps – if he doesn’t know about it then, by definition, it must not be important.

All in all, firms are better off to err on the side of culture over technical skill, but knowledge and skill matter, and a necessary element of a successful culture is an eagerness to learn.

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Filed Under: Culture & Leadership

Quote of the Month

May 13, 2013 by Bill Waddell 1 Comment

“Standard work followed on the front lines where the customers/end users hang around is like a Quality Fairy spreading magic pixie dust over the whole value stream.”

From the CEO of a very lean Indiana manufacturer in a recent email to me

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Filed Under: Execution Tools

OEE – Not Just for Machines Any More

May 13, 2013 by Bill Waddell 2 Comments

OEE – Overall Equipment Effectiveness – is like SMED – Single Minute Exchange of Dies- suffers from being narrowly named by its originators.  Just as SMED is a set of techniques and thought processes for changing production over from one product to another that applies to just about everything – not just exchanging dies – OEE applies to a lot more than equipment.  It applies to any and all work being done at a constraint.

Another problem with the perception of OEE is that many of it proponents see it as a universal cure, when it is enormously powerful at the constraints; not so much anywhere else.

OEE is basically the summary of three metrics:  Utilization – of the planned time the operation is supposed to be producing, how much time was it really producing?; Rate – when it was producing, how well did it produce compared the ‘standards’?; and Yield – how much of the stuff produced was any good?

That idea – that those three factors best measure throughout at the constraint – is irrefutable, yet far too many companies don’t apply it to people driven operations if they use it at all.  What is particularly interesting is how it plays right into the perceived problem of many companies that think they suffer from a shortage of skilled workers.

Case in point:  A company in New Zealand that correctly saw its constraint as an operation in which highly skilled welders did their thing.  Turned out that they did not have a shortage of highly skilled welders so much as they had their highly skilled welders spending a lot of time doing things other than high skill welding.  They spent a lot of time getting material, setting up jobs, doing welding that entry level welders could do, etc…  They didn’t need to hire more skilled welders – they just needed a helper or two in the cell to do that other work and increase the highly skilled welder utilization – the amount of time they did actual constraint work.

Similarly – on more than one occasion I have come across companies whose constraint was in engineering. By applying OEE logic to that constraint, and looking at how much time the engineers were actually doing work that took a degreed engineer it was obvious that more engineers weren’t needed. They just needed to reduce the huge amounts of time their engineers were spending in meetings, doing basic drafting work, and a lot of other things you don’t need to go to Purdue to learn how to do.

Of course, in both of the above instances the problem was utilization, rather than rate, and perhaps the bigger problem whether the constraint operation is machine or labor driven is a collective tunnel vision on rate.  Constraint problems are too often viewed as (first) a matter of getting people to work harder; then (second) solved only by adding more resources to the constraint – buying another machine or hiring more people.

Constraint

A classic, but simple, example of addressing utilization instead of beating up people or spending ore money is the company that simply juggled around break times to keep a constraint machine running eight hours a day rather than shutting it down for an hour a day for employee breaks; then going a step further by staggering employee daily start and stop times to expand it to ten hours a day.  From seven hours of utilization a day to ten – without spending an additional dime.  That simple, radical improvement is only possible when people use OEE thinking, and realize that utilization is the big opportunity – not the rate at which parts pop out while the operation is running.

 

What prevents this kind of thinking and improvement more often than not are senseless but firm HR policies that everyone has to take breaks at the same time, and everyone on first shift has to start and stop at the same time.

 

There’s the tip of the week:  Identify the constraint, apply OEE logic, take a hard look at rate, and do a little bit of creative thinking, then sit back and watch in amazement at the overall improvement.

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Filed Under: Execution Tools

Measuring Our Lives

May 10, 2013 by Bill Waddell 1 Comment

The story in the Wall Street Journal this morning about Henry Ford’s people policies is remarkable if for no other reason than the juxtaposition with the stories of the Bangladesh factory collapse death toll passing 1,000. Henry Ford stands in stark contract with the leadership of every company pursuing cheap labor. While Ford’s Sociological Department has been criticized as paternalistic and intrusive, the fact is it worked.  As the article points out:

“Today the Sociological Department might seem the essence of suffocating paternalism, and many felt it so even at the time. Certainly no other big industrial operation had anything like it. But with its medical and legal services, and the English language school it ran for the company’s thousands of immigrant workers, the department appears to have done more good than harm. In 1914 the average Ford worker had $207.10 in savings. For those who stuck with the company during the next five years, the average had risen to $2,171.14.

The reformer Ida Tarbell went to Highland Park planning to expose the oppressive Ford system. Instead she wrote, ‘I don’t care what you call it—philanthropy, paternalism, autocracy—the results which are being obtained are worth all you can set against them, and the errors in the plan will provoke their own remedies.’ “

More important it reflects Ford’s long term view of the business – spending money to take care of and develop people is not something that benefits the bottom line the next morning – and it reflects a genuine interest in the welfare of the people working for the company.

What possible conclusions can be drawn regarding the leadership of the companies like H&M, Nike and Walmart whose business plans revolve around taking advantage of countries so poor and corrupt that they facilitate the exploitation of people other than the direct opposite?  It seems pretty obvious that the leadership of such companies is tunnel visioned on the next quarter or two; and has little or no sense of humanity.

The legacy of lean – from its roots at Ford, its long term leadership at Toyota, and its hundreds of modern shining stars such as Barry-Wehmiller and Wahl Clipper – is one of commitment to the welfare of people.  That money can be made by embracing and committing to all of the employees is beyond question.  It is a well proven fact.

Ignorance is not a viable explanation for the executives at H&M, Walmart and elsewhere.  Paying women in Bangladesh pennies per hour for fourteen hour days in abusive, unstable and recklessly dangerous conditions is a choice they made.  It is not a mistake born of ignorance.  It is not a necessary aspect of business.  It is a deliberate choice made by leadership and one that is affirmed every day when they go to the office and analyze cost data telling them which third world country presents them with the most lucrative short term opportunity.

To paraphrase something I once heard Bob Chapman, CEO at Barry-Wehmiller say, ‘At some point every one of us is going to get put into the ground and someone will say something over our graves about the measure of our lives.  One thing is certain and that is that no one will care about the earnings per share, performance to budgets, or stockholder value we created.  The size of our bonus checks will not be the measure of our lives. It will be what we did with the opportunities we had as people of power and influence to touch people’s lives.”

The leadership of every company rationalizing its presence in death trap sweatshops in Bangladesh, Vietnam and eslewhere should be praying that Bob is dead wrong, or there will be a lot of thin eulogies in the coming years.

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Filed Under: Culture & Leadership

Beleagured Middle Management

May 9, 2013 by Bill Waddell 3 Comments

A piece on the HBR blog called “New Research: What Sets Effective Middle Managers Apart” addresses a real hotbed issue for lots of folks in business.  The author writes:

“Over the past 20 years, no group has endured greater pain and humiliation within organizations than mid-level managers (MLMs — managers from two levels below the CEO down to the line managers). Before the IT revolution, MLMs wielded genuine power within companies, acting as gatekeepers of crucial data, financials, and intelligence. Then, automation and the Web put senior executives in touch with their own front lines — and handed many MLMs their pink slips. MLMs who remained were labeled ‘dinosaurs’ or ‘overhead.’ ”

Let’s parse that a bit.  First, the author must be in his mid-40’s.  I don’t know that for a fact, but if he thinks middle management has been taking a beating for “the past 20 years” he it is only because he is not old enough to know that the problem existed long before his awareness.  In fact, middle management has been under siege since middle management was created.

Second, he writes that middle management’s woes happened because “automation and the Web put senior executives in touch with their own front lines”. I don’t know about his research, but my experience is that automation and the Web have little to do with whether senior execs are in touch with their front lines.  Execs that want to be in touch with their front lines are; and those that don’t care much about the front lines aren’t.  The Internet and automation have little to do with it, unless he is of the opinion that reams of data pouring forth from ERP systems put execs in touch with the front lines – a rather ludicrous proposition.

The basic premise, however, that “no group has endured greater pain and humiliation within organizations than mid-level managers” is true.  For as long as I have been involved in manufacturing I have known that middle management is under siege, both because I spent quite a few years working in middle management and saw it first hand, and because of all my years interacting with senior managers who have a propensity for blaming much of their companies’ woes on middle management.

A small percentage of middle managers are under siege for the simple reason they deserve to be.  The biggest obstacle to transformation is at the executive level, of course, but once overcome it is rare that a middle manager or two doesn’t plant his or her feet in the ground and resist with endless, irrational effort.  The common trait is usually a lifetime in the organization, with no experience or education in anything other than the way it has always been done there.  These few people truly do represent the often alleged middle management problem.

Most of the time, however, middle management is not the problem – they only seem to be because they are the ones caught between the proverbial rock and the hard spot.

Senior management wants commitment, engagement, participation and contribution from the front line workforce ….. but still measures middle managers and the company as a whole based on how hard they can pound on headcount and labor efficiency.

Senior management wants a high velocity, high quality supply chain that minimizes total cost of ownership ….. but measures supply chain people myopically on purchase price variance.

Senior management wants double digit inventory turns ….. holding the materials management people accountable for such results …. yet drives product managers and design engineers exclusively on product costs with no accountability for SKU and component proliferation.

Senior management wants maximum profits ….. yet sends sales people off on their own to maximize the top line, with operations in the next room to minimize costs …. completely disconnected when it comes to capacity utilization and the possibilities of level loading the factory.

The list goes on and on.  Senior management is on Mars and the lean efforts on the plant floor are in Venus, and middle management is held accountable for the impossible task reconciling the differences.

Blaming middle management occasionally has grounds for justification, but more often than not is due to senior management that expects a 21st century operating environment, while holding onto to the last century’s management principles, leaving middle management caught between the devil and the deep blue sea.

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Filed Under: Culture & Leadership

Enough ‘Internal Customer’ Nonsense Already

May 7, 2013 by Bill Waddell 3 Comments

In 1988 I wrote a workbook for the Emerson division I worked in called “Know Your Customer”, full of the usual stuff about identifying the next person or department in the chain who was your ‘internal customer’.  Each person was to identify their deliverables and meet with the ‘customer’ to determine the exact needs and set a measurement for improvement toward those deliverables.

I can be forgiven for creating such claptrap – after all that was 25 years ago and the term ‘lean’ hadn’t even been coined yet, let alone having Jim Womack tell us to ‘See the Whole’.  I have learned a lot since then and vow to never tell anyone they have an ‘internal customer’ again.

Perhaps Womack’s ‘Seeing the Whole’ was a bit too esoteric.  And when Eli Goldratt sagely advised the world that ‘Local optimization does not necessarily lead to global optimization’, perhaps he was not specific enough.  So let me be blunt about it – satisfying your ‘internal customer’ is a waste of time.

The whole internal customer thing is based on an assumption that functional silos are just the way things are and the way they have to be.  Your internal customer is the next silo over.  Engineering takes care of its customers in purchasing, and purchasing takes care of its customers in manufacturing, and so forth.  The problem is that each of those silo’ed, local ‘customers’ wants something that optimizes its own metrics and goals.

Within production, for instance, machining might be tasked with serving its customers in welding, and welding is told to take good care  of its customers in assembly.  But each of those groups idea of optimization is high labor efficiency – no downtime – full utilization of its overhead.  So what each wants from its upstream supplier is lots of stuff to work on – big batches, no shortages. Hardly a formula for optimizing lean flow.

And the bigger problem – to Goldratt’s point – is that sub-optimizing your ‘customer’ in order to really optimize an operational several steps down the line is quite often the right thing to do.  Spending an extra dollar in one operation in order to save two dollars elsewhere is best.  But you can only do this when everyone is seeing Jim Womack’s Whole.

Perhaps a case can be made for internal customers when it comes to purely administrative groups – accounting or HR, for instance – who are pretty much out of the line of fire in the value creation chain.  Anywhere else, satisfying the next customer in the chain is a meaningless objective, and quite often a destructive one.  I makes sense to big companies so steeped in silo thinking that seeing the whole is all but impossible.  They are unlikely to ever get terribly lean anyway, so it doesn’t really matter much.

For everyone else, however, the only customer everyone should be trying to optimize is the external one that pays in cash.

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Filed Under: Strategy

The Ideal Manufacturing System and My Hypocracy

May 5, 2013 by Bill Waddell 4 Comments

The post I put up last week slamming Big Data and ERP brought on spate of feedback that generally followed two lines of questions/criticism:  (1) You constantly slam big systems but don’t offer an alternative; and (2) Isn’t it a bit hypocritical for you to slam information technology yet you jumped ship from Evolving Excellence and into bed with iDatix – an information technology company.  Let me answer the first, which might help to explain the second.

ERP has its origins in MRP developed in 1961 on simultaneous tracks by Joe Orlicky from IBM and Ollie Wight, a consultant who went on to lead the APICS MRP Crusade.  This was long before the idea of lean was well formulated or known outside of a very few isolated companies. Lean accounting was not even an idea yet. It sought to optimize inventory, rather than reduce it. It assumed functional silos were the way things were done, and those originators had no concept of value streams.  It assumed push, rather than pull.  It had no consideration for visual controls, and assumed decisions could and should be best made by the computer itself and specialists in buying and planning roles sitting in front of computer screens in offices apart from the factory floor. It was created before the days of globalization and, obviously, long before the days of smart phones, the Internet and a very computer literate workforce.

While the ERP systems that have evolved from early ERP attempt to accommodate these things, with varying degrees of success, they are still constructed around the idea of functional organizations, give supremacy to GAAP accounting, and assumed to be collectors and manipulators of complicated data to be managed by highly trained specialists who will be the analysts and decision makers.  Just look at the weeks and months of training required upon implementation of one of these systems.

Manufacturing needs information technology support, but I believe the systems needed have to come from a clean slate, rather than a modification of traditional ERP.  The system needed should be built around these principles:

The purpose of the technology is to collect and communicate, not to control, censor or make decisions.

End to End Value Stream Structure

The structural backbone should be end to end vaue streams, rather than functional departments.  Just about every ERP system is primarily department and plant structured, with varying degrees of ability to look at information across value streams.  The ideal manufacturing system would not only be organized around value streams in a factory, but across multiple factories, even in multiple countries, even across multiple companies.  It would collect and organize data wherever the value stream goes.

Pure Data / Complete Transparency

The ideal system would not make decisions or show allocated costs. It would take data collected along the value stream and make it available as is – in its pure form.  All data would be readily available to everyone in the company. No where should either the system or a person be set up as a gateway deciding which data should be shared with whom, or manipulating the data to show people what someone else has decided would be helpful.

Support Decision Making at the Point of Attack

This is the biggie.  Decision making should be made by the people at the point of attack –production people, engineers, sales people – rather than managers, buyers, planners, staff people and others in offices away from where things are happening.  Of course those people have to have knowledge of the objectives and values of the company, and have to operate within a set of decision making rules.  At the end of the day, however, buying, production priorities, lot sizes, quality go/no-go decisions, pricing and delivery promises and the rest all have to be in the hands of the people on the front lines – the ones making things and face to face with customers.

Information Driven – Not Just Numbers

Information is not just numbers.  The system must include the numbers, of course, but also pictures and graphs, drawings and diagrams, words and email.  People making decisions in operations need to be able to see the whole picture – not just that which can be boiled down to numbers.

Accounting Primarily For Management Decision Making

The starting point for collecting and summarizing costs should be effective value stream decision making, rather than GAAP reporting.  Virtually every system in existence today is the opposite – built on the premise that all costs should be collected and summarized for GAAP, and management accounting should take that GAAP data and manipulate it as bets they can to make decisions.  The ideal system reverses this.  It starts with collecting and summarizing costs for management decision making – then tells the GAAP accountants to take that data and do whatever they need to do offline in some back room to satisfy GAAP.

This is where iDatix comes in. They are not a manufacturing systems company.  In fact they are manufacturing neophytes, but they very much want to learn.  What they are is a work flow – process, value stream – information company.  They are very, very good at capturing information in just about any form imaginable – numbers, output from big formal systems, email, pictures from smart phones, you name it – and communicating it very well up and down any value stream in just about any form.  The fact that the iDatix folks have no idea of how things are supposed to be done in manufacturing is actually their greatest strength. They are not bound by the assumptions and paradigms that shackle the ERP folks.

They work with me because they want to learn from me about lean manufacturing and lean accounting, and I get to learn from them what is possible and how the technology works that I see as the logical backbone of lean manufacturing technology in the future – beyond ERP   It’s that simple.  I have no idea where things will end up, but we like working with each other just for the mutual learning and to see where it goes.

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Filed Under: Execution Tools, Supply Chain

Big Data – The Antithesis of Lean Thinking

May 3, 2013 by Bill Waddell 5 Comments

It’s too bad lean thinking is free.  I suppose that’s not entirely true; a lean transformation actually costs a few bucks for the learning – consultants, books and training.  But it is nothing like the cost of an ERP system, and it pales in comparison to ERP thinking on steroids – ‘Big Data’.  Because the ERP and Big Data providers play in such a high dollar arena they can and do spend a lot on very focused marketing efforts.  IBM, a company that stands to gain quite a bit from Big Data becoming the focus of business management, is providing “software, curriculum, case studies—including guest speakers” to Rensselaer Polytechnic Institute, Fordham, Yale and about 300 other schools.  Too bad those schools aren’t cranking out kids steeped in lean thinking, but there is no one who stands to make a enough money from peddling lean in a position to buy college curriculums on such a scale.

There may well be a place for Big Data in science, but in business Big Data is the polar opposite of going to the gemba – lean thinking – and a singularly bad idea.  Effective decisions are made by empowered employees who share the company vision, and they are made one at a time at the point of attack, where the work is actually being done.  Big Data, like ERP systems, are built on the premise that mountains of data collected at the gemba must be gathered, sorted, analyzed and acted upon by smart people in far away headquarters buildings, in the offices of planners and buyers, by business analysts … just about anyone other than the people at the scene of the action the data describes.

“A May 2011 report by McKinsey Global Institute and McKinsey’s Business Technology Office found that by 2018, the United States could face a shortage of 140,000 to 190,000 people with deep analytical skills, as well as an additional shortfall of 1.5 million managers and analysts with the know-how to use the analysis of big data to make effective decisions.”  The fact that, when they are found, those “140,000 to 190,000 people with deep analytical skills” will all be 100% non-value adding wasted corporate bloat – just so much more overhead – is apparently not part of the equation. Not to mention that fact that the 1.5 million managers and analysts without sufficient analytical know how who are already squarely in the waste column.

To understand just how convoluted the thinking is, read this from the HBR Blog, called “The Value of Big Data Isn’t The Data”.

“Here’s an example. Imagine, for a moment, that you run an organization with multiple restaurant outlets and you have amassed point-of-sale data for each of your franchisees, but none of them are using that data because they just don’t get what they need from it. They need insight as to how their stores are doing and what they should do next. You need to give each of them a report that actually explains how they are doing in comparison to themselves over time, how they might compare to other restaurants, and where there might be shortfalls.”

So what sort of information Big Data actually do?  “Foot Long Hot Dogs were this week’s weakest menu item with average daily sales of fewer than 140 units. Bringing the store’s daily sales of Hot Dogs up to the same level as the co-op’s would add about $566 more profit each month. Over a year, that’s an extra $6,828. The store only needs to sell six more units per day to accomplish this.”

At how many levels is this scenario absurd?

For one, do the highly skilled analysts really think the guy running the hot dog stand doesn’t know that he would make more money of he sold more hot dogs?  Are they really so full of themselves (and so disdainful of people actually running things)?

Wouldn’t it be just as accurate – and a whole lot cheaper – to keep track of the number of hot dogs sold with hash marks on a white board in the restaurant kitchen? The problem with that is that the people actually making and selling hot dogs would have the data they need, but the big brains at headquarters wouldn’t … not a problem for a lean thinker, but a wholly unacceptable situation for a corporate bureaucrat.

Of course, All Business is Local.  Selling hot dogs at the restaurant is all about the local alternatives hot dog eating customers have, and absolutely nothing to do with how well another restaurant in another city is doing.  Using Big Data for benchmarking is of next to no value in the real world.

And of course, the biggie – “Bringing the store’s daily sales of Hot Dogs up to the same level as the co-op’s would add about $566 more profit each month. Over a year, that’s an extra $6,828. The store only needs to sell six more units per day to accomplish this.”

Typical headquarters analytical output – An overwhelming blast of the obvious, and absolutely nothing useful for the people who already know that, but are wrestling every day with how to sell more hot dogs.

That last point is pretty much the story of corporate information – for just about all big companies (the big ERP users and the ones chomping at the bit for Big Data) and too many not so big ones.  Data from the places where people are actually doing things – creating value for customers – is gathered and used by headquarters staffers (usually with little or no real front line experience) and manipulated to create ‘gotcha metrics’ that are intended to find any and every mistake the value creators make.  And make no mistake, the example in the article is just another example of this.

There is little in Big Data for people on the front lines, but their corporate critics will think they died and went to heaven with it.

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