Comments on: Explaining Lean at a Bar http://www.leanblog.org/2008/01/explaining-lean-at-bar/ Mark Graban's leanblog.org - Lean Healthcare, Lean Thinking, Lean Manufacturing, Toyota Production System Thu, 09 Feb 2012 15:26:57 +0000 hourly 1 http://wordpress.org/?v=3.3.1 By: Anonymous http://www.leanblog.org/2008/01/explaining-lean-at-bar/#comment-3050 Anonymous Thu, 24 Jan 2008 19:13:00 +0000 http://leanblog.bigbigdesign.net/2008/01/explaining-lean-at-a-bar/#comment-3050 I was sitting at a local bar recently and I overheard the bartender asking his manager if it would be OK to move some of the beer bottles around for easier access. He wanted to move the higher volume beers closer to the end of the bar where the wait staff picks up their drinks.<br/><br/>The manager shrugged his soulders and sort of agreed, but quickly changed the subject to something else. Later I had a chance to talk to the manager, and berated him for not taking his employee's suggestions more seriously. He later got with the bartender and worked out a plan to move the beer and "standardize" the system. There was a lot more motion waste that could be eliminated...I hope the manager got the message and opened up his mind.<br/><br/>Not sure of the point here...but another example that lean works everywhere. I was sitting at a local bar recently and I overheard the bartender asking his manager if it would be OK to move some of the beer bottles around for easier access. He wanted to move the higher volume beers closer to the end of the bar where the wait staff picks up their drinks.

The manager shrugged his soulders and sort of agreed, but quickly changed the subject to something else. Later I had a chance to talk to the manager, and berated him for not taking his employee’s suggestions more seriously. He later got with the bartender and worked out a plan to move the beer and “standardize” the system. There was a lot more motion waste that could be eliminated…I hope the manager got the message and opened up his mind.

Not sure of the point here…but another example that lean works everywhere.

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]]> By: Mike T. http://www.leanblog.org/2008/01/explaining-lean-at-bar/#comment-3046 Mike T. Thu, 24 Jan 2008 14:27:00 +0000 http://leanblog.bigbigdesign.net/2008/01/explaining-lean-at-a-bar/#comment-3046 Paddle - <br/><br/>I like that example. One of my favorites is similar. In order to give a customer a delivery date, it took 76 hours, of which only 27 minutes was "touch" time between sales and scheduling. We were able to develop a system within our own current processes that reduced that time to near instantaneous (dependent on IT system speed when entering a part number) on the majority of product in our first work cell. That change has been carried over to 2 other product lines now.<br/><br/>Our planners still have to plan 50-60% of all work in the plant before sales can quote a delivery date (we are a mix of standard and custom machining). However, we are steadily reducing that amount with the creation of part families and Lean processes. It is far better than the 100% planning we did just 12 months ago. Paddle –

I like that example. One of my favorites is similar. In order to give a customer a delivery date, it took 76 hours, of which only 27 minutes was “touch” time between sales and scheduling. We were able to develop a system within our own current processes that reduced that time to near instantaneous (dependent on IT system speed when entering a part number) on the majority of product in our first work cell. That change has been carried over to 2 other product lines now.

Our planners still have to plan 50-60% of all work in the plant before sales can quote a delivery date (we are a mix of standard and custom machining). However, we are steadily reducing that amount with the creation of part families and Lean processes. It is far better than the 100% planning we did just 12 months ago.

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]]> By: Jessica http://www.leanblog.org/2008/01/explaining-lean-at-bar/#comment-3043 Jessica Wed, 23 Jan 2008 21:46:00 +0000 http://leanblog.bigbigdesign.net/2008/01/explaining-lean-at-a-bar/#comment-3043 I normally find that after explaining what I do to people they tell me it's all common sense and organization. In most cases I would have to agree. I normally find that after explaining what I do to people they tell me it’s all common sense and organization. In most cases I would have to agree.

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]]> By: Paddle http://www.leanblog.org/2008/01/explaining-lean-at-bar/#comment-3042 Paddle Wed, 23 Jan 2008 19:10:00 +0000 http://leanblog.bigbigdesign.net/2008/01/explaining-lean-at-a-bar/#comment-3042 Hi, I use a good example of Waste with teams so they don't think waste removal is about removing them. <br/>I worked on a project (in a Telco) and we measured the "average" Move Add and Change (MAC) for a Managed Customer to take 79 hours. Of that 79 hours only 1 hour was touch time. <br/>So, when we are removing waste we're not talking about making people work harder, or faster just removing the dumb things in the process that stops people doing a good job, like jobs waiting in queues, jobs waiting in the wrong queue, going back for more information etc etc.<br/>Kevin. Hi, I use a good example of Waste with teams so they don’t think waste removal is about removing them.
I worked on a project (in a Telco) and we measured the “average” Move Add and Change (MAC) for a Managed Customer to take 79 hours. Of that 79 hours only 1 hour was touch time.
So, when we are removing waste we’re not talking about making people work harder, or faster just removing the dumb things in the process that stops people doing a good job, like jobs waiting in queues, jobs waiting in the wrong queue, going back for more information etc etc.
Kevin.

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]]> By: Mark Graban http://www.leanblog.org/2008/01/explaining-lean-at-bar/#comment-3041 Mark Graban Wed, 23 Jan 2008 15:51:00 +0000 http://leanblog.bigbigdesign.net/2008/01/explaining-lean-at-a-bar/#comment-3041 Matt - you are absolutely right!!<br/><br/>I cut short my re-telling of the story here on the blog. <br/><br/>I did explain to the bartender that Lean is about teaching people to analyze their own work and to come up with their own ideas... I was remiss in telling that part of the story here.<br/><br/>It's not about the wise-guy consultant having all the answers (I certainly tell my clients that!!). Matt – you are absolutely right!!

I cut short my re-telling of the story here on the blog.

I did explain to the bartender that Lean is about teaching people to analyze their own work and to come up with their own ideas… I was remiss in telling that part of the story here.

It’s not about the wise-guy consultant having all the answers (I certainly tell my clients that!!).

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]]> By: Anonymous http://www.leanblog.org/2008/01/explaining-lean-at-bar/#comment-3040 Anonymous Wed, 23 Jan 2008 15:48:00 +0000 http://leanblog.bigbigdesign.net/2008/01/explaining-lean-at-a-bar/#comment-3040 Mark -<br/><br/>I think you slightly missed the point. Lean is about teaching the bartender to recognize and solve her own problems. Getting her to engage PDCA will lead to a lifetime of improvements, whereas a consultant putting the soda mixers closer to her may get changed back with the night shift supervisor.<br/><br/>Best regards,<br/>Matt Mark -

I think you slightly missed the point. Lean is about teaching the bartender to recognize and solve her own problems. Getting her to engage PDCA will lead to a lifetime of improvements, whereas a consultant putting the soda mixers closer to her may get changed back with the night shift supervisor.

Best regards,
Matt

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]]> By: Mark Graban http://www.leanblog.org/2008/01/explaining-lean-at-bar/#comment-3039 Mark Graban Wed, 23 Jan 2008 12:32:00 +0000 http://leanblog.bigbigdesign.net/2008/01/explaining-lean-at-a-bar/#comment-3039 Andy - interesting story. You're right, standardized work approaches to error proofing aren't really the most effective. If the sub shop was a lean culture, how would they have responded to the defect? Instead of just putting the containers in the right locations, they could have asked why that occurred, immediately "swarming" the problem to discuss how to prevent it from occurring again, right? Andy – interesting story. You’re right, standardized work approaches to error proofing aren’t really the most effective. If the sub shop was a lean culture, how would they have responded to the defect? Instead of just putting the containers in the right locations, they could have asked why that occurred, immediately “swarming” the problem to discuss how to prevent it from occurring again, right?

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]]> By: Andy Wagner http://www.leanblog.org/2008/01/explaining-lean-at-bar/#comment-3038 Andy Wagner Wed, 23 Jan 2008 12:28:00 +0000 http://leanblog.bigbigdesign.net/2008/01/explaining-lean-at-a-bar/#comment-3038 I went to the sub shop at lunch the other day and I accidently got oregano on my sub instead of pepper. Not a big deal, but the lady explain that *somebody* put the canisters in the wrong slots. It's not a great error proof, and didn't work this time, but its low tech, easy to implement, and a great example of "everyday lean."<br/>The restaurant was too busy for me to explain how her job and my job were the same. ;) I went to the sub shop at lunch the other day and I accidently got oregano on my sub instead of pepper. Not a big deal, but the lady explain that *somebody* put the canisters in the wrong slots. It’s not a great error proof, and didn’t work this time, but its low tech, easy to implement, and a great example of “everyday lean.”
The restaurant was too busy for me to explain how her job and my job were the same. ;)

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]]> By: Richard Durnall http://www.leanblog.org/2008/01/explaining-lean-at-bar/#comment-3037 Richard Durnall Wed, 23 Jan 2008 11:24:00 +0000 http://leanblog.bigbigdesign.net/2008/01/explaining-lean-at-a-bar/#comment-3037 I like the example of the gadget that only allows a 'single' to be poured from the bottle as an example of a Poke Yoke.<br/><br/>I've got this Japanese drinks bottle that I carry around to show people the concepts of Poke Yokes and building quality in. <br/>The bottle has a marble trapped in a cavity in the top third of the bottle so that if you tip the bottle over the fluid pushes the marble into the mouth of the bottle and the fluid doesn't leak out. So how do you pour the drink you say? Well, there are 2 protrusions on the inside of the cavity that if you tip the bottle so that they are at the bottom they catch the marble and it doesn't block the mouth and stop the fluid flow. <br/>I think it's genius. My clients think I'm nuts. : ) I like the example of the gadget that only allows a ‘single’ to be poured from the bottle as an example of a Poke Yoke.

I’ve got this Japanese drinks bottle that I carry around to show people the concepts of Poke Yokes and building quality in.
The bottle has a marble trapped in a cavity in the top third of the bottle so that if you tip the bottle over the fluid pushes the marble into the mouth of the bottle and the fluid doesn’t leak out. So how do you pour the drink you say? Well, there are 2 protrusions on the inside of the cavity that if you tip the bottle so that they are at the bottom they catch the marble and it doesn’t block the mouth and stop the fluid flow.
I think it’s genius. My clients think I’m nuts. : )

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