Comments on: More Wisconsin Lean

By: Rick Foreman

Rick Foreman — Mon, 12 Nov 2007 19:45:00 +0000

Angela;
Being the 6th S does not make it the 6th most important in our organziation. I’m in total agreement with you that it should always be a number one priority, which reiforces the respect for team members and their well being. And as Mark stated, the auditing can be completed separately but why not maximize the time spent on the floor to identify waste to also identify potential safety issues? Many safety issues represent break downs in a process not being followed.

In addition, I agree that a poster is just a poster and should never be used to just walk and point. Yet, “training” posters, in “training” sessions can be valuable in presenting a solid “visual” for communication.

Great points by all!

Like or Dislike: 0 0

By: Mike T

Mike T — Mon, 12 Nov 2007 02:55:00 +0000

I’ve found that things posted are often ignored unless they hold meaning. Using generic 5S or Lean posters is all too often window dressing. If you aren’t going to post METRICS, then posting pictures of actual onsite issues, made into posters, would be the next option. Many printing companies have the ability to make customized posters out of your files, which at least grab the attention of those walking by…especially when they see one of their own work area.

Just a thought…

Like or Dislike: 0 0

By: Angela

Angela — Sat, 10 Nov 2007 16:52:00 +0000

Rick, very good points (and yes this is a good discussion). You are right; any improvement is considered Kaizen. Its literal meaning is, to take apart and make new. So knowing that you can’t really sort or set or shine etc…. until you have taken apart and made new your flow or process, because you don’t really understand what you will need.

I try to live by rule of thumb of “remember you are in someone else’s living room”. So how you guys do things are a part of your living room and if it works for you OK then. I worry, however, that even if you are considering safety as part of the S’s that it is considered the 6th S and not the 1st S. Safety should always be first and foremost in lean, it just goes along with the whole respect for humanity concept.
Thank you for this great discussion.

Like or Dislike: 0 0

By: Mark Graban

Mark Graban — Sat, 10 Nov 2007 15:41:00 +0000

Rick, I’m glad 6S works for you, that’s what really matters, I guess.

But I would recommend to others that 5S be kept separate from safety. 5S is about reducing waste through workplace organization (including the waste of people getting hurt, I guess). You can have focus on 5S and ALSO have a strong focus on Safety. It seems a bit “too clever by half” that some seem to think “Safety also starts with S… so it’s the 6th S!”

To me, it’s like saying you have four food groups and also water… water might be important but that doesn’t make it a food group.

Daily auditing of (and continual focus on) safety can be done independent of incorporating it into 5S.

Like or Dislike: 0 0

By: Mark Graban

Mark Graban — Sat, 10 Nov 2007 15:38:00 +0000

I’m with Angela. I think it would be rude to march an employee over to the poster to say, “here, read this.”

At best, a poster should reinforce a message already taught. We cannot rely on posters as a primary teaching method. You need to engage in a dialogue with employees.

At worst, posters are empty platitudes that management doesn’t believe in or live up to.

Like or Dislike: 0 0

By: Rick Foreman

Rick Foreman — Fri, 09 Nov 2007 19:39:00 +0000

With the definition of “kaizen” meaning small, consistent, and continual improvement, how can 5S or 6S not be viewed as a kaizen? At the most minimal level it would be a “point” kaizen. It may not be an event but any continuous improvement effort fulfills the definition of kaizen. In addition, we have seen substantial results from having the 6th S as safety. Lean supports the discipline aspect to follow through and learning to see. The daily auditing of 6S has brought a higher level of focus on the need for safety in all areas and partners perfectly with our safety coordinator and associated practices. With all that said, it really depends on the culture existing in a work place as to what will work most effectively. Lean is also visual and if used effectively, the “right” posters can support the focus towards a cultural change. I think it helps if the poster can be used in training sessions before being posted and then we have seen the need to change them out after awhile.
Great discussion!

Like or Dislike: 0 0

By: Angela

Angela — Fri, 09 Nov 2007 18:35:00 +0000

You had me until you gave an example. I would feel very degraded if my supervisor/manager did that to me. The posters are there for reminders (or decoration in some cases). Depending on the question asked it might be seen as an opportunity to coach or mentor and expand on the subject. A sensei would give the employee an opportunity to think through the problem they are facing and ask them questions and not just simply show it to them. Just reading what the poster says doesn�t mean they get the concept. When the question is being asked think about what they are really telling you�they are probably looking for further understanding.

Like or Dislike: 0 0

By: SysteMental Advisor

SysteMental Advisor — Fri, 09 Nov 2007 17:48:00 +0000

Posters can be great or useless. I believe the following makes them great:
- they must support ideas and methods used in the workplace (of course)
and here is the key:
- management must be trained to stop talking and start walking and pointing
When an employee asks a question, the manager should motion for the employee to follow, walk silently to the poster and point. Look at the employee and let the person answer their own question. Compliment the employee and walk away. Does this make sense to others?

Like or Dislike: 0 0

By: Angela

Angela — Thu, 08 Nov 2007 16:28:00 +0000

I find this article to be interesting in that the person who wrote it obviously isn’t on a lean journey. Also, even though any improvement regardless of its impact is considered Kaizen, I would not consider just doing 5s (or in this case 6s) kaizen. Isn’t 5s an activity that takes place after an improvement has been made?

I also have a problem with using as part of the “S” structure…Safety is always the number one rule in lean and when you separate it out into the 6th “S” you are making it an after thought, where it should be a constant thought.

I like the idea of the posters and keeping information prominent for the employees, but it sounds like too much of a good thing. I have a feeling that the posters in the plant are viewed more like artwork than their daily “beatitudes” in you will. On going awareness to me are Gemba Walks, Morning Market and talking with the people who actually do the work…you can’t achieve that in a poster.

Like or Dislike: 0 0

By: Dean Bliss

Dean Bliss — Thu, 08 Nov 2007 15:49:00 +0000

There are some good things going on in Wisconsin – places like Airens, ThedaCare, and others. One thing I’ve founsd with dealing with the media, though, is that it’s difficult to get very deep with the understanding of what Lean is. Superficial knowledge – just enough to get the article written – leads to misleading conclusions and flip statements about what Lean and Toyota are.

Like or Dislike: 0 0