Tag Safety

Why Pursuing Zero Harm Is a Powerful Driver of Lean in Any Industry

TL;DR: Pursuing zero harm isn’t about unrealistic goals or punishing people for failure. It’s a leadership choice that creates psychological safety, accelerates learning, and strengthens Lean systems. When organizations treat safety–physical, emotional, and professional–as a non-negotiable value, improvement capability follows…

Kaizen at Garrison Brothers: Improving the Bourbon Bottle Dipping Process

I'm excited that our sold-out "Symposium on Learning Organizations" group will be visiting Toyota's San Antonio plant on Wednesday. Later that day, we'll be touring the Garrison Brothers Distillery and, on Thursday, we are using their "barrel barn" as a venue for "Open Space" discussions, the Red Bead Experiment, and more. We have a group of 40 from many industries attending and we might run a similar event in a different location in the future.

I've blogged about Garrison Brothers and my stint as a bottling line volunteer before...

In that post, I shared pictures of me working to dip bottles of bourbon into a sealing wax. I was wearing a winter coat because it was February in Texas and there was a bit of snow and ice that week.

When I was back there recently, I saw some additional improvements that seem like "Kaizen" to me. 

Toyota Rotating Shifts: Questions About Fatigue, Safety, and Respect

Prolonged worker resting at car assembly plant, with cars in progress and assembly workers in background.

There's much to admire about Toyota and even regular readers of this blog might throw the "fanboy" label at me. Toyota employees in San Antonio have a lot of positive things ("pros") to say online about working there. But, the overwhelming "con" is the rotating work schedules - being on days for two weeks then switching to nights for two weeks. Where do a priority on safety and "respect for people" enter into the discussion about which shift pattern is safest, most effective, and most fair?

Solar Eclipse: Supply Chain Challenges and Eye Safety Considerations

Any rare event creates a number of challenges when it comes to manufacturing and supply chains. We're seeing a pretty historic "spike" in demand for products like the inexpensive glasses that allow one to safety view the eclipse (our friends in the totality zone can look at the totally-eclipsed sun safely, but that's the only time).

You could call it "supply chain challenges" or a "lack of planning on my part," but I cannot find eclipse glasses anywhere. There are MANY articles online about this widespread problem -- it's been impossible to buy "eclipse glasses" anywhere. Why is this? What could have been done?