The construction industry has been mired in an environment that has been siloed and antiquated for years. The view has been that things have always been done a certain way and there is no reason to change. Meanwhile, numerous industries have embraced lean methodologies and have significantly reduced waste, improved efficiency and delivered higher quality products which meet or exceed customer expectations. Surveys show that at least 50% of processes involved in planning and construction are wasteful. The industry has adopted lean construction methods, which are starting to change an industry that lagged behind others.

Learn more here about lean construction!

The post [VIDEO] Lean Construction Methods Transform the Industry appeared first on 6sigma.

Muda is all about waste and Lean manufacturing is about eliminating Muda. It is any activity that adds no real value to the product or service being created or delivered. The diligent attention to the elimination of waste in how work is performed is a fundamental tenet of Lean manufacturing, the operational excellence strategy that was developed over many years and is widely used in business today.

The post [VIDEO] Muda Is All About Waste appeared first on 6sigma.

Muda means waste and refers to a wide range of non-value-adding activities; eliminating waste is the key to efficiency. When you look at the Toyota Production System (TPS), eliminating Muda waste is one of the main principles of the Just-in-Time system. Some things that are considered waste are unnecessary financing costs, storage costs and worthless stock of old items. Toyota divides Muda into seven categories:

1. Transportation – increases risk of product being damaged, lost or delayed.
2. Inventory – Outlay of capital that doesn’t immediately produce income.
3. Motion – Damage inflicted through the production process.
4. Waiting – Product sitting idle.
5. Over-processing – Doing more work than is necessary.
6. Over-production – Making more product than is required by the customer.
7. Defects – Replacing faulty parts or products.

Processes consumes resources and naturally, waste can occur. The more resources that are used, the more opportunity exists for waste. The tools of Lean manufacturing and the TPS help focus on the elimination of Muda waste and create a heightened awareness. Understanding exactly what waste exists and where it is exists is crucial to any Lean manufacturing process. Even though products differ between manufacturing organizations, lean practitioners understand that the types of wastes are very similar.

The post Elimination of Muda is the Key to Efficiency appeared first on 6sigma.

Since 2006, Great American Cutlery has built the reputation for making the finest quality traditional pocket knives in the US. Located in historic Titusville, PA, the brand focuses on a hands-on process which yields the most beautiful and high quality pocket knives on the market. Their products exceed expectations from customers by producing a product that first became a mainstay in the late 19th century.

Check out the unique insights to the process that is Great American Cutlery!

The post [VIDEO] Great Eastern Cutlery Factory Tour appeared first on 6sigma.

With Tesla and Elon Musk hitting the news almost everyday on a variety of topics other than manufacturing, it seems like a good time to refocus and revisit one of the most innovative manufacturing processes in action. Tesla, under the leadership of Elon Musk, is breaking the mold in manufacturing and doing just what everyone said he couldn’t do. Musk is confident that Tesla will become the example for mass car production of the future.

Take a few minutes with Elon Musk and enjoy the tour!

The post [VIDEO] Tesla Factory Tour With Elon Musk appeared first on 6sigma.

Walters & Wolf are a premier commercial cladding manufacturer. They have established the industry reputation of being able to produce products of every cast and color, to precise and exacting specifications. They draw and engineer all systems in-house, both shop and fabrication drawings for project submittals and shop fabrication and field installation. Their quality and customer satisfaction could not be reached without engraining a firm core of Lean manufacturing in their culture and everything they do.

Take a few moments and learn from Walters & Wolf!

The post [FACTORY TOUR] The Lean Journey of Walters and Wolf appeared first on 6sigma.

Marketing professionals are starting to take their cues from the manufacturing industry and adopt lean agile principles to improve performance and value. A common tool in lean agile practices used in manufacturing are sprints. The two practices are complementary, and achieve significant results when applied appropriately.

Recently, a marketing director with a Fortune 100 organization observed the lean agile process of sprints in their engineering team. They would use month long bursts (sprints) to create and test the potential value of projects. At the end of each sprint, the engineering team would examine what worked and what didn’t. If it was deemed a success, the process was adopted. If it didn’t, then the process was eliminated from consideration. The marketing director found inspiration in the process and success of the engineers, and imagined the same success in the marketing department. Research shows that 77% of marketing departments had adopted lean agile practices in the past five years. Of those respondents, 67% of those organizations increased revenue and profits. This clearly shows the potential of lean agile practice performance in the marketing profession.

Marketing Lean Agile Sprints Work

In this specific marketing department, the director adopted the lean agile process of their engineers and started on a new journey of excellence. The director prioritized a list of their most important projects and delayed lesser ideas until later months. They went to work and ran sprints on their top priorities. When they made their marketing process more customer centric, they also found they started sharing a common language with others in the organization. The overall team started working together and better understanding individual roles. The marketing department developed the process to where they would run a large project and two smaller ones each month. They were able to focus the efforts of marketing to better fit into what the rest of the organization really need form the team. They developed a year-long plan for their sprints, which significantly improved the overall effectiveness of the marketing team. The marketing department was better able to say no, not right now to requests and really focus on what made a difference for the entire organization. The entire team was able to become more comfortable with both failure and honesty. It was like new life came into the department. A mindset developed within marketing that they could experiment with campaigns to reduce workload and effort when putting a new product into the marketplace.

The post Marketing Professionals Adopt Lean Agile Techniques appeared first on 6sigma.

In taking a cue from manufacturing, marketing departments are embracing the principles of lean agile practices. Research shows that over the past five years, 77% of marketing departments have embraced lean agile principles, and 67% of those have shown increases in both revenue and profits. Needless to say, lean agile principles are making an impact in the marketing community.

Please take some time and watch this informative video on the topic!

https://youtu.be/j-r5W_Eq4G4

The post [VIDEO] Lean Agile Sprints for Marketing appeared first on 6sigma.

When first learning about TPS and lean, most become focused on the tools. They tend to be flashy and lend to endless discussion about technique and application. But as you gain experience and understanding of lean and TPS, an epiphany occurs. The true essence and spirit of the applications are about continuous improvement and respect for people. The are truly the two pillars of lean and TPS. Waste reduction and management tools are not pillars of the methodology.

The essence of methodology is that each individual employee is given the opportunity to find problems in his own way of working, to solve them and to make improvements.

Wakamatsu and Kondo, Toyota experts

The essence of lean thinking and TPS is simply put. Keep the focus on building people, then building products, which includes creating an environment of challenging the status quo. The true brilliance and strength of the TPS and lean thinking is the ability to harness the intellectual power of the average employee. This concept is lost on many organizations who get themselves lost in the tools and miss the obvious simplicity of the concepts.

The concept of respect for people not just about the customer or end user. It refers to everyone inside and outside of the organization who has contact with the process. This means line workers, support personnel, vendors and supply personnel. If you follow through with this principle, you will continually analyze the process and seek perfection with involving the customer. This will nurture the ability of the organization to self-identify problems and lead to continuous improvement, or Kaizen. Ultimately, the organization will start to challenge everything and embrace change with ease. More important than the actual improvements, the true value of continuous improvement is in creating an atmosphere of continuous learning and an environment that not only accepts, but actually embraces change.

The post TPS and the Two Pillars of Lean appeared first on 6sigma.

Leading in turbulent times requires a deliberate shift from command-and-control towards a collaborative style of leadership. This may be easier for some than others. It requires a shift in mindset! The idea of collaborative leadership requires individuals at all levels take initiative and act in ways that supports the achievement of the vision, purpose and objectives of the enterprise. The freedom to take risk, to fail, to engage in constructive conflict, to participate in decision making and to experiment, learn and innovate. This is collaborative leadership.

Take the time to watch this informative video!

The post [VIDEO] Collaborative Leadership is a Mindset appeared first on 6sigma.

The true concept of lean and TPS has two main pillars. These two pillars are respect for people and continuous improvement. Many organizations who try and embrace lean thinking and TPS are often distracted by the tools, instead of focusing on the true strength of lean thinking. Accepting the concepts of the two pillars will allow organizations to challenge everything and embrace the mindset of change.

Check out this informative video on the Two Pillars of TPS and lean!

The post [VIDEO] The True Focus of Lean and TPS appeared first on 6sigma.

The concept of collaborative leadership seems foreign to some professionals new to a leadership role. Most newly anointed leaders anticipate an environment where they are streaming orders down the line and their staff are jumping into action. Things are getting done as long as they seem to be in control, barking orders and expecting complete subordination of their authority.  It is an idealistic world that truly only can be successful in the most limited environments or in times of life-or-death situations. The practice of collaborative leadership can be crucial in times of uncertainty or turbulence, but is also a driving element in the lean manufacturing environment. Simply put, it creates a collaborative environment where people can unite with purpose, with clear vision and a solid set of values.

Leaders practicing in an environment of collaborative leadership have a purpose and vision, with character and values that are unwavering.  These elements blend together and create passion, but that passion must begin with the leader. Others will not follow a leader that lacks passion, simply because they lead by example. This element of passion in leadership creates the spark that drives others to initiate actions independently and step up to the challenge.They are will to take on ambitious responsibilities and accept the risks associated without  fear.

The elements of purpose, character and values brings a leader forward in the work environment. One of the hardest lessons learned in that environment is that they are really never in control. It is understood that people comply with authority when the leader is present. The real key to success is what they do in the absence of authority. Collaborative leadership principles demand leaders that can lead without the safety net of a title, position or authority of a superior. This doesn’t mean that you cut deals or accept substandard performance. It simply means that your drive, passion and commitment inspire others to follow your lead. 

Finally, collaborative leadership focuses on developing people and other leaders at all levels. It instills the concept that everyone is a leader.  Everyone has voice that is respected and that they are expected to take the responsibility for their actions. This means that mistakes are no longer there to be documented and considered as punishable infractions. They become opportunities for learning and development. You must take your people outside of their comfort zones and encourage them to succeed.

There are many elements involved in collaborative leadership. They require a leader to give up their authoritative tendencies, get out of their office and join the work environment they are responsible for. It requires character, passion and the establishment of trust. It is truly the foundation of a successful team and the collaborative process. It is all about the people. 

The post Collaborative Leadership Is a Different Skillset appeared first on 6sigma.

Ben Hartman is the author of The Lean Farm, a book on minimizing waste and increasing efficiency on the vegetable farm. He has farmed full-time for the past ten years with his wife, Rachel, in Goshen, Indiana, where they’re both making a living on less than an acre of production, selling 90 percent of their produce within ten miles of the farm.  Hartman has applied the lean methodology on the modern market farm, including the basics of creating value, establishing pull with customers, and the 5S pillars of the lean cycle: sort, set in order, shine, standardize, and sustain the cycle.

Check out this educational podcast with Ben Hartman!

The post [VIDEO] Learning More About Lean Farming appeared first on 6sigma.

Kaizen is the Japanese word for “improvement.” In business, Kaizen refers to activities that continuously improve all functions and involve all employees, from the CEO to the assembly line workers. It also applies to processes, such as purchasing and logistics, that cross organizational boundaries into the supply chain. It has been applied in healthcare, psychotherapy, life-coaching, government, banking, and other industries. By improving standardized processes, Kaizen aims to eliminate waste. It was first practiced in Japanese businesses after the Second World War, influenced in part by American business and quality management teachers, and most notably as part of the Toyota Way. It has since spread throughout the world and has been applied to environments outside business and productivity.

Now, take those simple processes from the factory floor to the home front and you might just find some success. With our world becoming more and more hectic in the digital age, we are losing the battle of a work-life balance.

Check out this amazing video on Kaizen in your personal life.

The post [VIDEO] Take Kaizen Home and Be More Successful appeared first on 6sigma.

Are you feeling overwhelmed and out of control? Not really a surprise for many, considering the demands on our lives in this digital age. We are spending more time at work than any other generation in American history. As a workforce, Americans lose more paid leave from work each year than any other country. Our workdays get longer and they don’t end when we leave the workplace. Our smartphones keep us tethered to the office, and we can never really disconnect until late into the evening. Then, we have to try and balance our professional demands with our personal lives. Spouses, children and extended family demand our time as well, but seem to be getting the short end of the stick for most American workers.

So the question becomes, how do I find balance when the demands on our time continue to escalate? There are a wide range of options available for the busy professional who needs to find balance in his or her life. Browse the internet for five minutes and you will find a long list of self-help experts and gurus who claim that they can make things all better and find the balance you are seeking. But, how do you find the right help, and can you fit the cost into your budget? Things just get more and more complicated, don’t they? Well, a simple answer may be just simple techniques that are practiced in many organizations around the globe and they get results. Just take a look at the Kaizen philosophy and really understand how that applies to your personal life, just like the processes on the factory floor. Kaizen may be just the solution you are looking for!

Kaizen took hold in the years after WWII with the Japanese and the Toyota Production System (TPS). It is based on the belief that continuous, incremental improvement adds up to substantial change over time. When teams or groups implement Kaizen, they circumvent the upheaval, unrest, and mistakes that often go hand-in-hand with major innovation. It’s fitting that the Japanese word kaizen translates to good change. You can take those techniques and apply them directly to your personal life and affect real change. The core principle of Kaizen is waste reduction, so take stock in what you are doing and make some changes. Look at what you need to stop doing that is not productive or unnecessary and make some changes. Look at the time-wasters that sneak into our daily activities and carve them out. Prioritize your tasks and find simpler, easier ways of getting things done. An audit of your daily calendar will truly be an eye-opener for most people.

Daily consistent improvement is the key to success. Think small in the beginning. Those little changes will, at first, free up 15-20 minutes a day. As you make improvements, those changes get a little bigger. Now, you are not having to work through lunch, or you have actually made the time to catch a kid’s soccer game or make it home on time for date night, without missing any key objectives. They real key to success is to constantly look at ways to improve, become more efficient at tasks or build better habits. Just be patient and you will find success in the process and a much need balance between your personal and professional life.

Read more here about Kaizen. It just isn’t for the factory floor anymore!

The post Kaizen Methodology For Boosting Personal Performance appeared first on 6sigma.