Some succeed because they are destined to.
Others succeed because they are determined to.
Henry Van Dyke
Some succeed because they are destined to.
Others succeed because they are determined to.
Henry Van Dyke
Toyota’s secret to the long term success of their Toyota Production System (TPS) is actually pretty simple! It’s not even a secret. It’s also really straight forward. It’s captured in a single word. Know what it is?
During and since working at Toyota, I’ve been asked many times what the secret sauce is that makes Toyota and TPS such a long term success! It’s absolutely true that TPS is a comprehensive multi-dimensional system or mechanism about which many books have been written explaining it in great detail. There is no doubt many powerful principles and tools within it. It is built on the fundamental principles of respect for people and continuous improvement. My intention is not to diminish the integration or thoroughness of TPS, but my single word response to the secret sauce question is,
I wholeheartedly believe in respect for people and have a huge passion for continuous improvement, and the best way to create, drive and sustain both is by Gemba!
In addition to providing a means to achieving the principles of respect for people and continuous improvement, the top 5 reasons for conducting gemba are revealed in the spelling of the word itself and are:
Go See the actual condition – in similar fashion as the saying “a picture is worth a thousand words”, seeing is believing! Gemba allows all participants to see the same thing firsthand. The good, bad and the ugly! This is powerful because there is nothing left to someone else’s interpretation and/or communication. There is no opportunity to hide, exaggerate, or underestimate the conditions or impact through misunderstanding, poor communication, or lack of familiarity of the process. Gemba also provides alignment of what is happening or not happening.
Go and see is so powerful, I once scheduled a meeting with the President of Toyota, on the roof!
Engagement – Gemba is an incredible way to engage openly between all levels. Asking questions to understand surfaces issues, barriers, abnormalities, ideas, and potential solutions. It provides opportunities for operators to voice their opinions and become directly involved in being part of a solution. Gemba facilitates clarity of leadership direction, and teaching and learning opportunities of all involved. It is an effective way to follow-up on previous actions and their effectiveness. Gemba also is a great time for leaders to challenge, encourage, motivate, and of course recognize the efforts and results of their teams.
Man, Machine, Material, Method (4Ms) – Gemba allows teams to focus their attention on the 4Ms to identify barriers and wastes impacting the operation or process. The focus of a Gemba could focus on all the 4Ms, several, or a specific one depending on the desired intent or the situation. The focus on the 4Ms helps train and develop the team on waste identification and is the engine of continuous improvement.
Barriers – Another reason for gemba is to identify barriers either creating a form of waste in the process, or impacting the completion or desired impact of identified actions and solutions. This is very important in order to first identify necessary actions for improvement, and then when reviewing previous actions to demonstrate support to the team, speed up progress, and keep the team motivated by reducing frustration.
Action– Gemba must result in some kind of action. To me this is not only a must, I believe it is unavoidable. When everyone sees the same things creating impact, questions are inevitable, followed by the generation of ideas to resolve the issues. This occurs by default. Prioritization and elimination of the identified actions need to happen next. Once the immediate actions are determined and agreed upon, ownership and completion dates are imperative. Timely follow-up of all actions is very important to drive urgency, identify barriers and where help or clarification is needed, and provide additional opportunities for all aspects of engagement.
So not only are the reasons for Gemba hidden in plain sight of the letters of the word, the reasons for Gemba also propagate the entire philosophy of continuous improvement by naturally creating a never ending cycle of Gemba.
Are all Gembas the same? “Follow” my website, to receive the next post, “The Different Types of Gemba”.
You can email me with any questions at glennsommerville@hotmail.com, find me on Facebook at https://www.facebook.com/glennsommervilleL2R/, or on Twitter at https://twitter.com/gsommervilleL2R.
If you are enjoying my posts and find the information useful, please “Follow” me by entering your email in the follow box on the right-hand menu of my website www.glennsommerville.com
At age 40, I visited seven people who had guided me along positive paths when I was a child. I wanted to thank each one for shaping my life. To my surprise, only three remembered me. Like stones dropped in a pool of water, the words of advice you give today may ripple outward into many lives and many tomorrows.
Don Dougherty
Don’s words are so accurate! Don, you need to know that you didn’t just receive ripples created by seven people, but you dropped many stones in that pool yourself that have propagated ripples to many, many more. I was fortunate to be one of them. I met Don over twenty years ago when he coached and mentored me and my team on one of the pinnacle milestones of my career. We have stayed in contact since then and Don has continued to be a mentor, advisor, and friend to me. Thanks Don! No doubt you have given more than you received!
Do you sometimes find your team doesn’t understand your priority? If so, they are probably confused by your actions not your words. So what can a leader do to ensure their actions speak louder than their words?
In a previous post, A Big Problem With Problem Solving, an example was given where the team believed the leaders placed a higher priority on productivity over quality which ultimately resulted in a significant quality defect. I received a question from a reader that many leaders often face, and struggle with, on how best to address the following type of unfortunately common issue:
The perception of team members that some attributes (i.e. cost and delivery) take precedence over other attributes (i.e. quality) has concerned me several times. How do you suggest this can be changed?
A leader’s actions not only have to align with their words, the actions must speak louder than the words! Also, actions have to be consistent and unwavering from the words particularly when in a time of pressure or crisis. For example, if you always say safety is the most important thing, that you care for your team, and that you will not risk their safety for any reason, and then when you are under the gun to deliver on time, you instruct your team, or otherwise turn a blind eye, to by-pass a safety standard, process or policy, you’re done. These are opportunities where your actions can speak louder than your words. Imagine if during this same example, you shut down the operation until it could be done safely? Of course there may be a negative impact such as missing on-time delivery, but over the long term, and as it relates to the culture and relationship with your team, which is more important?
Two real examples come to my mind that emphasize these points very well. The first related to a safety issue that was identified but didn’t cause an immediate safety risk. Only under certain conditions and situations was there some risk. Many involved believed that with additional training and other controls in place, the risk could be adequately mitigated. Further more, the condition had existed for some time but had only just been identified and become known. Stopping the operation would no doubt impact the customer and add cost to the business. The timeline to address the issue was significant, costly, and would impair the operation until addressed. The leader involved, demonstrated conviction to their words of safety first, and shutdown the operation and kept it down until the safety issue was properly addressed.
I was directly involved in this second example and remember the situation like it was yesterday! Production was behind schedule and as we worked hard to catch up, the quality indicators started to decline but remained within target. On this particular day, the first passed yield dropped significantly, meaning a lot of rework would be required and the actual completed volume would be lower, adding to the stress of the situation. We had always and consistently communicated that our top priority, second only to safety, was quality. I called the management team together and requested that we shutdown the plant and conduct a quality stand-down with the entire plant. They looked at me like I was out of my mind! They raised concerns with the additional lost volume this action would result in, not to mention the costs! We shutdown and communicated the quality concerns, what the top issues were, what the operators could do to improve quality, and reconfirmed our leadership priority and commitment to quality over productivity/volume. The recognition and appreciation from the team was incredible, which boosted the morale and pride of the operators for being part of an operation that placed quality ahead of productivity. They wanted to believe!
They wanted to believe!
These examples describe real life crisis situations many leaders have and will no doubt face in their careers. It is during these times, that true leadership and commitment to a leader’s words, values, and standards is tested and demonstrated. It is during these times, you either build or destroy your culture and leadership trust. These decisions are never easy, even though they should be, because of the other ramifications and consequences they create. However, I’d suggest that typically those consequences are short term focused. If you lead with the long term in mind, the decision is clearer and easier to make.
The same holds true for a non-crisis day. Your actions must be consistent with your words. You can’t walk by or ignore anything that doesn’t align with your words. You must take action. For example, no matter what else is happening at the moment, walking past something or someone that is unsafe when you say safety is your top priority, completely discredits your words of the past, present and future. Look for opportunities to emphasize your priorities and reinforce your words every chance you can find. Always explain “why” one thing is a priority over another. If you need to focus on something else that might give the perception that your priority has changed, explain why you are focusing on the other and that it has not in fact superseded the higher priority.
You can email me with any questions at glennsommerville@hotmail.com, find me on Facebook at https://www.facebook.com/glennsommervilleL2R/, or on Twitter at https://twitter.com/gsommervilleL2R.
If you are enjoying my posts and find the information useful, please “Follow” me by entering your email in the follow box on the right-hand menu of my website www.glennsommerville.com