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Monday, January 28, 2008

LeanBlog Podcast #35 - David Meier

LeanBlog Podcast #35 is another discussion with David Meier, co-author of the book Toyota Talent, written with Dr. Jeffrey Liker. In this podcast, we follow up our previous discussion (Podcast #31) to talk about the upcoming Toyota books, as well as some of the leadership challenges that companies face with working with Lean.


If you enjoy this podcast, I hope you'll check out the rest of the series by visiting the LeanBlog podcast main page at http://www.leanpodcast.org/.




MP3 File (Right Click to Save-As)


Keywords and Main Points, Episode #35



  • The next books coming in the series - Toyota Culture, Toyota Process, Toyota Problem Solving

  • Hearing comments about how companies have trouble sustaining Lean after 3 or 5 years -- why is that happening and what's missing?

  • Talking about the LEI survey on why companies struggle with Lean (link)

  • How is the Toyota San Antonio plant creating a system of systematic continuous improvement?

  • Following the stand problem solving methodology to find out why a company is struggling with Lean...

  • Instead of being punative, leaders need to be more inspirational

  • Need to move away from blaming

  • Leadership has to communicate the message

  • His website: http://www.thetoyotaway.org/


If you have feedback on the podcast, or any questions for me or my guests, you can email me at leanpodcast@gmail.com or you can call and leave a voicemail by calling the "Lean Line" at (817) 776-LEAN (817-776-5326) or contact me via Skype id "mgraban". Please give your location and your first name. Any comments (email or voicemail) might be used in follow ups to the podcast.


Click here for the main LeanBlog Podcast page with all previous episodes.



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Tuesday, May 29, 2007

LeanBlog Review: Toyota Talent

Toyota Talent is the third, and newest, book in the "Toyota Way" series:
They are a trilogy of books, but each is very different and has its own unique place in the lean literature. These books are unlike a series of novels, such as the Harry Potter series (I presume, not having read them), where you necessarily have to read all of them.

The Toyota Way is an outstanding overview of the Toyota methodology, philosophy, and management system. The book does an excellent job of describing how Toyota is, in a high-level manner that can be applied across industries, including the gap between manufacturing and healthcare. The Toyota Way is one of the very first books I would recommend to any executive or manager to get a sense of the overall Toyota system (helping them avoid the urge to implement selected lean tools without understanding the entire system.

The Toyota Way Fieldbook was not, as some might have thought, simply a paperback version of The Toyota Way. The Fieldbook was an altogether different book, with a different purpose. As effective as The Toyota Way was, the Fieldbook was necessary for filling in the gaps in a reader's mind, someone who thought, "Ok, I know how Toyota is.... but how do *I* get there??" The Fieldbook is more of a guide for "how to implement" the Toyota Production System. The Fieldbook is one I would recommend to managers or active practitioners in a lean transformation.

Now, the Toyota Way team is setting out to write what should be considered an altogether new trilogy and series of books -- related to The Toyota Way and the Fieldbook, but with a different purpose. The three books in this series are:
  • Toyota Talent
  • Toyota Process
  • Toyota Problem Solving
These books will, I would assume, follow a similar structure and tone, each diving deep (Very deeply, based on Toyota Talent) into a single core idea in the Toyota Mindset.

Toyota Talent is *NOT* a book only for H.R. professionals. If you think that developing people is the job of H.R., then don't even bother reading this book. Developing people, getting the most out of your organization's human potential, is the job of every leader in a lean organization. If your idea of developing people is to fire your "bottom 10%" each year, replacing them with better talent then, again, save your $20 and buy another Jack Welch tome. I saw a copy in an airport bookstore the other day, which was nice to see, but it also struck me as odd, since that seems like the executive market that the publisher is targeting. I'm happy for Liker and Meier if that helps sell more copies.

So who *should* read this book, then? Well, I think different parts of the book have different audiences. The first section, Getting the Organization Ready to Develop Exception People, consists of four overview chapters. For the executive reader, I'd recommend the first two chapters, which provide a concise summary of the Toyota Way philosophy and how developing people supports lean and, more importantly, long-term business success.

So I'm saying the executives shouldn't bother learning the details of Toyota Talent? In a perfect world, or an ideal lean organization, maybe executives would eat this stuff up. But, I think it's more realistic to have executives read the first few chapters so they can understand what their organization will be implementing. If time is tight, the rest of the book might contain too much detail. Let the line leaders and implementors digest the content and start implementing, coaching the executives with the distilled version (and key points) of Toyota Talent. If you disagree with that approach, please comment using the link at the end of this post.

Now, to the meat of the book. Toyota Talent really breaks new ground, rather than re-hashing things we've all read before. Unless you have a strong background in the Training Within Industry methodology, much of the book will be an eye opener, giving you approaches and tools that can be implemented immediately. Toyota Talent is written more along the lines of the Fieldbook, in the sense that the authors give you specifics that can be implemented, rather than just a description of Toyota's system.

If you're an active lean change agent (as a line manager or a consultant), this book is a must read. The book demystifies the world of Standardized Work and breaks it down into something concrete and practical. The book not only explains how to develop and implement a standardized work system, it also (in typical Toyota style), explains much of the "why" -- why do we implement standardized work?

The book sets a tone of not standardizing for the sake of standardizing. The methodology focuses on figuring out what matters, and doing so by getting input from the value adding employees. Focusing on safety and quality is a key part of Toyota Talent's methodology. The book gives a method for breaking down the work content of existing jobs, using highly repetitive manufacturing examples as well as a highly variable healthcare environment (a nurse in a hospital). The method is presented in a way that DOES make sense for both environments, which might be a surprise to many readers.

Toyota Talent covers the entire standardized work process:
  • Deciding what to standardize
  • Breaking work content down and documenting standardized work
  • How to train in a highly effective manner
The book builds upon the Training Within Industry methodology, as written about in other books. But, Toyota Talent explains how Toyota built upon the TWI framework to create something uniquely Toyota, but adaptable to almost any environment.

Even with my caveats (and maybe my cynicism about executive attention spans), I highly recommend Toyota Talent. It carves out a very unique, and helpful, place in the lean literature. It's a very readable book, written in a down to earth and practical style.

Have you also read the book? What did you think? What did you find to be helpful?

If you have questions, I can try to line up responses from Liker or Meier, in another blog post (maybe David will post or comment himself) or via a Podcast interview.

Updated: David Meier *has* agreed to do a Podcast interview, so let me know (via a comment or email) if you have a question for him.

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Thursday, May 03, 2007

New Book, "Toyota Talent:" Out NOW

Toyota Talent

Update 5/6/07: The book is now shipping from Amazon

I had the pleasure of reading a pre-publication version of this new book from Prof. Jeffrey Liker and David Meier. You know Jeff from The Toyota Way (and my Podcasts with him) and David from his co-authorship (with Jeff) of The Toyota Way Fieldbook (and my Podcast with David).

Toyota Talent is refreshing in that it really adds to the Lean literature in the important area of Standard Work and the development of people. The book probably has a less broad audience than The Toyota Way, given its more detailed treatment of the topic, but this book will be invaluable if you are working with actual Lean implementation on a daily basis -- in manufacturing or healthcare. There are examples from multiple industries included, in fact, so this isn't just a book about Toyota.

From the back cover:

Leading Toyota authorities Jeffrey Liker and David Meier give you the keys to growing top performers from within through a detailed process of preparation, training, and follow-up. Drawing upon Liker's detailed study of Toyota's manufacturing, technical, and service organizations across the globe, and Meier's deep experience gained from working with some of Toyota's best sensei, the authors bring the company's proven practices to life through insight and exercises, enabling you to:
  • Define your organizational needs and objectives
  • Create development plans for all employees
  • Grow your top talent from within
  • Analyze routine work and ancillary tasks
  • Break down a job for effective training
  • Break the cycle of poor training and results to create a cycle of continuous learning and improvement
There are many helpful tips, including this one from page 135:
"The "real world" of the nurse's job requires flexibility and the ability to respond to the ever-changing situation. We hear this same objection in manufacturing or other fields where the work appears to be highly variable. It is assumed that the nurse's job must be made routine like an assembly line job. Herein lies the mistake. It is not the intent of standardized work to make all work highly repetitive; it is the intent to define the best methods and to reduce variation in the work method as much as possible."
That is outstanding advice for applying Standard Work to different healthcare environments. People say they don't want to be turned into robots. I think this book will show you a practical approach to Standard Work development and training that respects people as living, thinking, creative humans.

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Tuesday, April 24, 2007

"Toyota Talent" out April 29

Amazon.com: Toyota Talent: Books: Jeffrey Liker,David Meier

This has been an exciting week for me. Monday, I met David Mann, author of Creating A Lean Culture, in person and had a chance to hear him speak and to speak with him at length. As I've mentioned before, his book is outstanding and has really been having a positive impact on folks in healthcare who are working to move from "Lean project" to "Lean culture."

Today, I was able to meet and talk with David Meier, another friend of the blog, sometimes poster, and co-author (with Jeff Liker) of The Toyota Way Fieldbook and the upcoming Toyota Talent. I was fortunate to read a preview copy of Toyota Talent and I'm sure it will be a very useful addition to the lean library. I'll try to post a formal review ASAP.

Both Davids were generous with their time and their thoughts, which I appreciate. I'd encourage you to check out their Podcasts (linked to their names above) and their books.

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Tuesday, January 23, 2007

LeanBlog Podcast #17 - David Meier, "Lean in China"

LeanBlog Podcast #17 is a discussion with a good friend of the Lean Blog, David Meier, a former Toyota Georgetown Group Leader, founder of Lean Associates, and the co-author of the excellent book, The Toyota Way Fieldbook, and the upcoming Toyota Talent, due out in April (both co-authored with Jeff Liker, check out my Podcasts with him here and here). In this Podcast, we talk about David's recent first hand experiences with factories in China. Are there labor shortages? Is there a lot of waste in Chinese factories? Do the Chinese have good management skills at this point? What lean methods did David see in China? We'll cover all this and more.

If you enjoy this podcast, I hope you'll check out the rest of the series by visiting the LeanBlog podcast main page.



MP3 File (Right Click to Save-As)

Show Notes and Approximate Time, Episode #17

  • 2:00 Overall, pretty surprised, Chinese factories are in good condition, but there are some real labor shortages growing, intense cost pressures from other countries (India, Vietnam, Turkey, etc.)
  • 3:00 Lots of struggles from the supply chain side and total cost, "China isn't as great a deal as they anticipated in the beginning" (inbound supply chains)
  • 4:00 "One company had 160% turnover last year"
  • 4:15 Local management isn't that strong, so companies bring in their own management(which is costly to bring in foreigners)
  • 4:45 David was frustrated to see the same challenges and problems in China that are typical here, including the "kaizen blitz" mindset (companies aren't getting long-term satisfaction or a sustainable process)
  • 5:50 Saw one company (a clothing manufacturer in China) that took "one piece flow" to such an extreme that it was costing them in other ways, companies are missing the point of what Lean really is
  • 6:30 More on the single piece flow situation - are you implementing single piece flow or are you improving performance?
  • 10:00 What about Chinese factories and their metrics and goals? David was surprised to hear how everyone was focused on efficiency and labor cost
  • 11:00 David saw a lot of Non Value Added activity (20-30% of people's activity) because ofthe way work was structured
  • 11:40 "Big shortage of Industrial Engineers in China"
  • 12:45 Chinese managers learn "mass production management" or lean management methods?
  • 13:45 "I didn't see any factories that would be a model of lean" and David was visiting companies who had expressed some interest in being lean
  • 14:15 What lean methods did David see at Chinese factories?
  • 15:20 David says there is a general lack of understanding about how to use "Value Stream Mapping"
  • 17:15 David and Jeff Liker are working on a new book about systems and how to develop the system properly, how to use the system (such as Kanban) to drive continuous improvement
  • 17:45 An earlier new book, "Toyota Talent" is coming out in April
  • 18:30 After the Fieldbook, David and Jeff realized there were some topics they could really expand on, Toyota Talent, lean systems, and problem solving.
  • 20:15 A preview of Toyota Talent... didn't see much "Standardized Work" in China, the depth of lean there isn't as great as in the U.S. The book looks at how you break down jobs and train people.
  • 22:00 People look at Toyota and assume that standardized work only applies in repetitive, highly cyclical jobs (but Toyota has a lot of jobs that don't fit that mold)
  • 24:30 David comparing the high turnover in China with the high turnover in fast food and how McDonald's simplifies things, uses standard work, makes it visual, etc. But why do they accept the turnover?
  • 25:45 The NPR piece on In-N-Out Burger and how they value employees.
  • 26:45 David points out how you have to look at total cost, not just the low hourly labor cost
  • 27:30 Is everything going to inevitably move to China? We're trying to compete against that with Lean, reducing costs through Lean methods and improved/faster response.

If you have feedback on the podcast, or any questions for me or my guests, you can email me at leanpodcast@gmail.com or you can call and leave a voicemail by calling the "Lean Line" at (817) 776-LEAN (817-776-5326) or contact me via Skype id "mgraban". Please give your location and your first name. Any comments (email or voicemail) might be used in follow ups to the podcast. Click here for the main LeanBlog Podcast page with all previous episodes.

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Monday, January 22, 2007

Next Podcast: David Meier

Sorry for the delay. I was in a nice rhythm of having a new LeanBlog Podcast every Monday, but I fell behind with the football games on Sunday. I'm not sure if the customer "takt time" for podcasts is one week, but that's the cycle time at which I was running.

Podcast is now out.


I'm almost done editing and putting the notes together for my discussion with David Meier about Lean in China. David is a friend of the blog, a sometimes Blogger himself, and is the co-author of the excellent The Toyota Way Fieldbook and the upcoming Toyota Talent, due out in April (both co-authored with Jeff Liker, check out my Podcasts with him here and here).

I'm hoping to have the Podcast out late Monday night. If you have suggestions for future Podcasts, please email me (see the left-hand column) or post a comment here.

For an earlier Podcast about Lean in China (with Jim Womack), click here.

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Tuesday, January 09, 2007

Lean Board comments by David Meier

Message Board, direct link to David's Post (scroll down the page)

If you haven't been visiting the LeanBlog Message Board, here are some comments by David Meier that you might want to check out (no registration required to read).

His post begins:

-------------------------------

I would have to say that I have seen a trend towards companies that are making a second attempt (or even third attempt for those who were into Just In Time in the ‘80s) at lean. I do admire people who get up and give it another shot. That is really what is necessary. It is a never-ending journey and I really try to get people to eliminate the term “failure” or “good/bad” and “right/wrong” from the conversation because there really is no such thing. Basically, you either get the result you desire, or you don’t. Either way you are going to try again and improve, change, modify, to get a new result, so it is just a series of steps continuously improving.

Anyway I have given some thought to the question of why there seems to be more “failure” with lean implementation than “success” and here are a few observations.

1. Most people (I am going to use people because people make up a company, and a company is really just the people) fail to establish a motivation for implementing lean. I usually start with myself and ask, “Why do I want to do this?” “What is my personal motivation?” Then I need to ask other people, “Why do you care?” You must find out what will motivate other people as well as yourself.

-----------------

David continues with a very long and worthwhile post. Check it out, again the link is here:

Message Board, direct link to David's Post (scroll down the page)

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Friday, January 05, 2007

Problem Solving Example

Are you working on the True Problem?

Lean Blogger David Meier tipped me off to this interesting post about root cause problem solving, an example inspired by the book he co-authored with Jeff Liker, The Toyota Way Fieldbook.

Check out the link and take a read. Good stuff. Why do we wear shorts and t-shirts in the house when it's cold, anyway?

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Tuesday, January 02, 2007

Lean Challenge Response: David Meier

Here is a response to the Lean Challenge contest entry (click here to read the situation submitted by Rich, a blog reader). Click on the "Contest" link at the bottom of this post to see more responses. If you have advice for Rich, please leave a comment on the main page here.

This response is from author, consultant, and Lean Blog contributor David Meier. David is a former Group Leader at Toyota and is the co-author of the The Toyota Way Fieldbook and the upcoming book Toyota Talent, which can be pre-ordered on Amazon.com.

David wrote a very long response to Rich's challenge, so we created a PDF file that you can download here. Below is the introduction to his advice:

There are really several questions and issues here. One of the problems with lean or TPS is that no issue really stands alone. These issues are all intertwined into your overall lean system, which is what makes implementation such a challenge, and of course so interesting! If it were an easy task everyone would do it, and there would be no need for highly capable lean leaders! I like how Rich concluded his question— he goes on teaching and coaching in spite of the numerous challenges. These are just a few of the many challenges! We must continue on in spite of the challenges.

I will break the questions down into three main themes:

  1. The issue of urgency.
  2. The use of systems and standards and the need to deviate from them.
  3. Creating effective standardized work and audits for leaders.
Click here to download David's full Challenge Response (pdf file).

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Thursday, October 26, 2006

Scientific proof that change is difficult!

By David Meier, Lean Associates

Mark,

I wanted to share two recent articles that discuss new scientific evidence related to the change process. Many of your readers who are involved in efforts to make change will appreciate the fact that change is difficult. One major take-away for everyone- the article states that no one likes change thrust upon them. It is much better to establish the overall expectation and then allow people to discover their own solutions. I think this is a key method used by Toyota. Each individuals creative effort is employed to solve problems and make improvements in ways which work best for the member and team.

Read the articles carefully and between the lines are ideas on how to help people accept change more easily. The articles state that the resistance to change is rooted in our primitive brain and is quite natural, so for all change agents out there who are facing the challenge maybe learning how to be patient as people discover their solutions is advised. For the first article in CIO magazine there is a side bar which has 10 tips for change. Be sure to check it out.

CIO Magazine: The New Science of Change

strategy+business: The Neuroscience of Leadership

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Wednesday, October 25, 2006

Welcome to the Blog, David Meier

As you may know, if you're a regular Lean Blog reader, this isn't a solo venture. I'm happy to have other bloggers on the site and I'm happy to add one more: David Meier, co-author of the outstanding book The Toyota Way Fieldbook and co-author (again, with Dr. Jeff Liker) of the upcoming Toyota Talent. His first post will appear tomorrow morning, so stay tuned.

I've emailed and talked with David a number of times over the past year and he has been a good friend to me within the lean world. I'm hoping that he will contribute to the blog as time allows and we are planning on doing a Podcast interview in the near future.

Here is a link to David's bio at his site, Lean Associates. I like David's perspective on lean since he was a Group Leader at the Toyota Georgetown (TMMK) plant and has worked hard to share real and practical TPS approaches and methods with the lean community. Welcome to the Blog!

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Monday, September 25, 2006

Great Kanban Story from David Meier

Here is a story from David Meier, a former Group Leader at Toyota and the co-author of The Toyota Way Fieldbook and the upcoming Toyota Talent (April 2007).

He writes:
I am sure you have experienced the problem of how to attach kanban to cardboard boxes. We did not have too many cardboard boxes at Toyota so for the few we had it was not a big deal. We used bungee cord or rubber bands or slipped the kanban under the flaps.

In other companies there are many more boxes and it is a big challenge. A company I work with had a great idea. It started with one guy walking around Wal-Mart one night looking for an answer to this dilemma. He finally realized that a wood screw poked through the boxes would work so he experimented with it. It worked pretty well, but then there was a screw dangling from the kanban when not on the box.

Some time later another guy (his nick-name is Skinny) was working with the materials guy (nick-named Moose- I am not kidding those are their nicknames and I don’t know their real names) and Skinny relied on his previous experience in retail to develop an idea for the kanban. He suggested using one of those devices used to attach plastic tags to garments to attach kanban to boxes.

They bought a heavy-duty hand-held tag gun and gave it a try. As you can see from the photos it works great. This is one of the cleverest ideas that I have seen lately and since you are the king of kanban I thought you might like to spread a good idea. (Click on the pictures for larger views)


The company is MI Windows and Doors in Gratz, PA and the guys are coming up with some great ideas that I wanted to share. They bought the tag gun from ULINE at the link below. Make sure to but the heavy-duty needles. They are also looking at the unit that holds 1000 tags but I told that was over-production.

Here is a link for the gun.

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