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!

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Boeing builds the venerable 737 workhorse at a rate of one every nine days! That is a monumental feat of Lean manufacturing. The Boeing 737 is the workhorse of many airlines across the globe, flying short and medium range flights. It was originally designed in 1964 and took its first flight in 1967. In 1968, Lufthansa airlines put the Boeing 737 into service across their service areas. Since its inception, the aircraft has been through numerous upgrades and modernization changes that continue to make it an in-demand aircraft among airlines. As of 2006, there were an average of 1,250 Boeing 737s airborne at any given time, with two either departing or landing somewhere every five seconds. 

Watch this video and see how they do it!

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Take a step back in time with a vintage Honda factory tour! Since 1959, Honda has been setting records. They are the largest manufacturers of motorcycles and internal combustion engines in the world. In 2001, they became the second largest Japanese auto manufacturer. Honda also manufactures garden equipment, marine engines, personal watercraft, power generators, and other products. Since its inception, Honda has applied the principles of Lean manufacturing, and this timeless video will take you back and show you how they do it.

Take some time and enjoy a flashback in Lean manufacturing!

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The concept of Hoshin Kanri provides clarity and focus to an organization, by aligning strategic goals through all levels of an organization. It creates an organic flow of information which runs through an organization, where goals run down from management, through the mid-level operation to the production floor. In return, the flow reverses and the production floors provides resulting actionable data flowing up through mid-level operations to management, thus providing alignment.

Taking the first step of implementing Hoshin Kanri begins with developing long-range strategic goals for the organization. A good rule of thumb is to limit the strategic goals applied to five or less to be truly effective. It also allows the focus of energy and resources on what efforts are most important to the organization. Remember, if everything is important, then nothing is important. They should also be either evolutionary or revolutionary. Evolutionary is incremental achievements through continuous improvement. Revolutionary is all about taking big strides, making breakthrough changes with dramatic scope. Both types of goals are crucial to the life of an organization.

The next step would be to develop the tactics for implementing the goals identified. This step is the purview of middle management operations. They are the experts at implementing and allocating resources. There should be a respectable period of thoughtful back and forth between management and mid-level management to ensure goals are clearly understood and that there is a strong alignment between tactics and goals. Over time, tactics can be adjusted and should be, as things changes. Results must be measured and calibrated.

In the final stage, production operations at the supervisory and team levels work out the details on strategy and clearly understand the strategic goals. This is where the action takes place and success will be measured. Management and leaders must stay connected with actions being implemented, mainly through Gemba walks and monitoring of production data flowing up from the production floor.

The flow created with Hoshin Kanri closes loops and ensures focus, clarity and highly efficient operations. It allows organizations to be agile and flex to changing situations in an efficient manner.

Learn more about Hoshin Kanri and download a template

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Kanban is a lean method to manage and improve systems and process across an organization. The methodology balances the demands with available capacity, and improves the handling of system level bottlenecks. The Kanban board is a tool within the methodology which will allow the visualization of any process. The goal of a Kanban system is to limit the amount of work in process so the work flowing through the system matches its capacity.

Check out this informative video on the Kanban Board!     

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Key performance indicators (KPIs) are among the most common tools used in business to help manage more effectively and guide the progress of the organization. They provide clarity to murky issues and put the spotlight on potential opportunities. Key performance indicators can help an organization predicate an impending storm and avoid potential downfalls.

Leaders often misunderstand or overuse the term. They tend to relate key performance indicators to any type of business data measurement. To be effective, key performance indicators need to be metrics that matter to the business of the organization. KPIs need to be linked to the overall strategy of the organization, which means to first identify what matters the most and what provides the proper measurement. Leaders and key stakeholders can monitor these indicators over time and adjust plans and programs as needed to improve the KPIs in support of the organization’s strategic goals. The ideal process for identifying and implementing key performance indicators involves the leaders and contributors regularly revisiting and revising the measures. This is a fine-tuning process, which takes time and diligence by all parties.

Key performance indicators can shape strategy and fact-based decision making inside organizations. It doesn’t matter how brilliantly you’ve aligned your KPIs to your strategy, or even how brilliantly you have captured and presented the relevant KPIs. If leaders aren’t using your KPIs to inform their decisions and drive performance, then they are wasting time and effort. A well-designed set of KPIs should provide a clear indication of current levels of performance and help leaders make better decisions that brings the organization closer to achieving its strategic objectives. By avoiding the pitfalls, leaders can ensure KPIs are designed, implemented and used exactly as they were intended – to help the organization succeed and avoid the inevitable storm.

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Push and pull models of manufacturing are two major approaches implemented by organizations. The decision on which approach to use is often based on their business strategy. Push and pull-based models in manufacturing starts at the planning phase and continues through the execution stage.

Watch this informative video on Push/Pull Production!

https://youtu.be/a7YvJB0n16I

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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.

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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!

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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. 

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Most definitions of lean manufacturing refer to the reduction of the Muda (7 wastes) as the main focus. Few definitions of lean differentiate between the different types of waste and seem to purely focus on Muda. The Toyota Production System (TPS) sees waste as being three — Muda, Mura and Muri — something that many lean practitioners seem to have forgotten. The best way to tackle a problem is to remove the root cause, therefore the focus of any waste reduction program should be on removing both Mura and Muri, as this will automatically remove much of the Muda (7 wastes) in the workplace.

The overall aim of any quality improvement technique is to improve the profitability of the business. To do this you have to be able to recognize these three wastes for what they are and be able to tackle the root causes.

Muda – Commonly referred to as the 7 Wastes and are non-value adding processes or actions.

Mura – Seen as unevenness or a lack of stability and flow. This drives the creation of Muda.

Muri – This is simply defined as overburden. Expecting too much, with defining process or not having the correct skills or tools.

The three Japanese Mu words are part of the Toyota Production System (TPS). Each of these is a type of waste and are recognized by the Japanese as part of a business improvement initiative. The elimination of waste has come to dominate the thinking of many when they look at the effects of the TPS because it is the most familiar of the three to implement. In the TPS, many initiatives are triggered by inconsistency or over-run reduction, which drives out waste without specific focus on its reduction.

In today’s competitive environment, a focus on reduction of waste is crucial to the success and profitability of any organization. Eliminating waste makes it easier to see and find problems, which is the first step to solving them. It removes frustrations, which improves worker and customer satisfaction.

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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.

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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!

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Are you ready for the Super Bowl? Later this week, there is going to be over 100 million people tuning into that uniquely American sporting event. Friends will gather, grills will be lit and drinks will be chilled all to cheer for their favorite team in the ultimate sporting challenge. You can guarantee a large number of those fans will be enjoying the game from the comfort of their La-Z-Boy recliner. You can also bet that La-Z-Boy has been spending their season preparing for the NFL season and the Super Bowl with the same eager excitement as the fans, through the use of lean manufacturing principles and practices.

La-Z-Boy Inc., is one of the largest furniture manufacturers in the US, employees 8,950 staff worldwide and reports sales in excess of $1.5 billion. Beginning in 1927, the founding partners invested in a small furniture business in Monroe, Michigan. Their goal was to design a chair for people to take advantage of nature’s way of relaxing. The initial production model was a wooden slat porch chair with a reclining mechanism which allowed the seat to move forward as the back reclined. Soon, they were manufacturing an indoor version which was upholstered.

The organization takes pride in its ability to deliver custom furniture to the consumer consistently in four weeks or less. That’s no small achievement, considering that consumers can choose from approximately 175 furniture styles and almost 1,000 fabric and leather coverings. Their five assembly plants are operated using lean manufacturing principles, which position them well in such a highly competitive environment. The La-Z-Boy supply chain has been identified as one of the most capable in the industry, and customer satisfaction remains high through their efforts and attention to processes. Not only are their lean manufacturing processes both agile and efficient, they are safe. Three of their operations set industry records in 2017 for safety and their flagship operation in Dayton, OH exceeded 10 million hours without a lost time accident.

So, when you sit back and relax on a La-Z-Boy for the Super Bowl, know that you are relaxing in a product that is manufactured by true lean professionals whose focus is your comfort.

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What can be said about sales. It is that mysterious department located away from everyone else. You see them come and go, but you don’t really know what goes on behind closed doors. They are never seen at meetings or training because they are out in the field.” So, there is the common misconception that they are not really part of the operational organization and are left alone to their own devices. If that were true, then why the heck are they even here? How possibly could you get the sales staff “back into the fold” for the organization, hold them accountable and apply lean principles to their workflow? If you step back from the misconceptions and emotions of the situation, you will find that accountability and lean principles can apply to a sales force and can be very effective.

One thing you must keep in mind is that sales is about revenue, which is the lifeblood of any organization. Whether you like it or not, without sales, an organization will dry up and wither away. Organic sales from existing customers will only support things for so long. New business or fresh sales must be consistently infused into an organization to keep growth moving up. Most CEOs from Fortune 100 companies will tell you that every young leader in an organization must spend some time in sales. It is crucial for building a successful leader. It provides a unique perspective and understanding of how the entire business holds together from start to finish. With that in mind, it takes certain skills and a mindset to be a successful sales representative. However, those exceptionally successful in sales will also tell you that the core of the sales cycle depends not only on relationships, but using the same processes every time to close deals.

When applying lean principles to sales, we need to be thinking about who are our customers, how do we value them, and how do we create value for them? Then you must understand what experience do we want to create through the entire journey from before they buy, through the buying process, and implementation. You must have a clear idea of this philosophy, or you can’t make the decisions that enable you to implement the philosophy through our organization to the customers. You must align sales with the customer’s buying process, maximizing their ability to win is fundamental. There are any number of ancillary processes in the sales process, which must be aligned.

Lean principles from manufacturing can be directly applied to any sales process, across any industry. It is really just about understanding the customer thoroughly and then applying the processes that are unique to a sales organization to achieve results. It takes a constant focus with a dedication to continuous improvement to achieve results.

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