JIT for sustainability!

What do you see in the pic... 

Some may respond, "I see... 

- two paper cups \ glasses of water, 

- One of the cups \ glasses half full, the other one empty! 

- cups \ glasses waiting to get disposed!" and so on!

Can you make a story of it!

(Immediately after boarding a flight) I'd asked for half glass of HOT WATER!

The airhostess promptly fetched me a full glass of lukewarm water!

Second time after a while, while she was on a service round, I 'showed' her the old cup and indicated to fill in it half (glass of) HOT WATER again!

She (ignored the old paper cup &) served me lukewarm water (by mixing cold water in it) in a fresh paper cup!

What's the learning!?

My learning is: 

1.. Ask for what you want (here the HOT WATER) clearly specifying (in this cup "please" &) not to mix cold water in it! Merely showing the cup may not be enough. The supplier need to clearly communicate her inability, if any, to supply as per specifications.

2.. Never take the customer's specification for granted. Always confirm specifications of her need!

3.. It's good to share such stories to train your own staff back in your office as also at your home about the - importance of customer specification\s in the JIT¹ way as in point-1 above! - need for sustainability (to re-use) specially when the customer has specified so! - need to express inability, if any, to supply with justified reasons in an honest, caring & gentle manner - importance of observation power and alertness to learn from each moment & from each happening around in order to generate opportunities for improvement (OFI) in self if not in others. The latter may be out of one's control!

4.. Although the above behaviours look commonsensical, they rarely happen. So change in attitude is needed at personal level reflecting it in the desired behaviours.

5.. Rather than being a mere spectator, an observer around may take lead in appreciating such desired behaviours. Positive reinforcement thereby may help recurrence of such desired behaviours!

By the way, this is not a story! 

It's an actual customer-experience. It actually reinforces - how much waste (here the cup & the water served in excess over the demand) gets generated in each of such transactions between a customer and a supplier! - how badly there is a need to educate and train people to reduce waste and help the sustainability movement in order to reduce global warming!

¹ JIT is - Just (i.e. exactly) what's needed, - Just (i.e. exactly) when it is needed, - Just (i.e. exactly) how & how much amount is needed! JIT approach to work provides unending OFI's or Kaizens as done by many companies the world over.

Change is a hearty game!

I wash my cup after tea and plate after food almost immediately. As much early (JIT) you do so, as much lesser resources you consume. Because, they are easier and faster to wash with less water when they are still wet.

The other day I'd to do it with left hand because one of the fingers was swollen after clipping off my nails.

It was difficult for me because I am a right-hander.

Usually any change is difficult but possible. Try signing with your left hand if your are used to doing it with your right hand.

I'd to get the senior management team of a company to try this out the other day. The reason was their impatience on the change management initiative in their company.

It was just about a few weeks having begun the initiative. Each visit the managers would be anxious to know when would their subordinates change their work habits for the better.

Change management is about commitment to change self first (PQI, personal quality initiative). It's about putting in concerted and continued efforts during the process because it's more to do with head (mind) and heart rather than hands (physical actions) alone.

Listening to other's 'voices' (be it your employee or customer or any stakeholder for that matter) actively plays a major role in the change management process. It's not merely hearing but it's about hearing them tactfully and tenderheartedly... Hear-T in short! Active listening creates an emotional connect or a connection with their heart.

Mind (head) always connects a little later. Mind connects only after the heart gets connected. Heart itself gets connected if they see your concerted and continued actions towards the desired change rather than empty speeches and promises.

Their actions to change their habits as desired is the corollary thereafter!

Also read a few relevant blogposts hereunder: Please do consider leaving a comment or sharing this post.

Mosquito to teach patience
Voice of Customer

No Time? Micro-Meditate!  
What do you do when a dog barks at you?
How To Make A Difference 
Conscious Of Self-Esteem
Catch a Butterfly

Overworked? Tension? CPU of the mind hung-up? 
Do you exercise your choice meaningfully 
IQ-EQ-or-SQ: What-is-more-important? 
Eternally Happy! 
In-a-problem? No-problem! Dwell-a-while! 
I am afraid ! What do I do !! 
Fearful-Of-Death-of-Birth
Take Habits For A Ride 
Happy-Birthday-to-Youooo
Do You Celebrate Mean-or-Green 
Big-Be Or Bug-Be ! 
Raam or Krishna-Shyam: Tell me Hey Raam! 
Are You Good If Others Are Bad?  
Want Need-Or-Want 
Love is Care.. Care is Love !  
Deity is in the eyes of the beholder 
Success-or-failure! What-do-you-like?
Ball-Basin-Team Combine !  Maketh The Smile Divine !! 

Can-changing-thoughts-change-a-nation

Digitally Lean, Physically Fat

Just heard from a marketer about Digital-Lean! that he was trying to sell. No wonder there's a pull of  IOT (internet-of-things) all around now.

Seems to be a new jargon though, like Lean-Six-Sigma that evolved while maturing the Six-Sigma initiative of Motorola, GE, et all.

Such jargons that evolve, rather 'revolve' at regular intervals confuse the practitioners.
That was a point of my contention in one of my books 'Stay Lean, Make Planet Green".

Proponents of various management techniques (under jargons) such as BPR, TOC, 6-Sigma, etc. in past advocated hardly anything different than the original JIT thinking itself of Toyota to attain Lean. Nothing is wrong with these approaches except a major difference that the same proponents tried to catch up with either under different jargons or under a few augmented versions.

Most of these approaches focused on working top-down on obviously visible problems (as the links of a steel chain, say, that had already given way) that had reached a crisis stage. Naturally such crises problems demand radical changes. JIT philosophy instead, as a preventive culture, exposes potentially weak (but so far ‘invisible’) links before they actually turn weak and before they give way.  

Apart from the above, the 'people' aspect of problem solving (the Hitozukuri) also got ignored in the former approaches in their enthusiasm to invent newer mathematical models, tools and jargons.

Behavioral part of JIT instead builds and nurtures an army of soldiers capable of exposing and fighting potential weak links. Thereby it preempts failure of the process of making and delivering (the Monozukuri) of the offering.

So, the Fad-of-the-day, Tool-focus is the culprit of confusion, if any.  

Only when it was realized that the 'Toyota approach' is 'much more proactive' and ‘heart-full’ than what met the eyes and gray cells of a few fly-by-night consultants on a study mission to Japan, that the ‘augmented’ versions of their management tools appeared on the horizon of  the management world.

After the Re-engineering as a tool; to BPR; to Re-engineering of Management, etc.; the latest example is the re-christening of highly digitized statistical '6-Sigma'! It was jargonised as 'Lean-6-Sigma' having realized that '6-Sigma' as a measurement was already in use at Toyota. 

Exactly on similar lines, Toyota already had its very own invented SIS, strategic information systems technology in the 1960s. Toyota did the IOT (internet of things) in its own way then. It had its own towers in order to telegraphically release management information so that they could respond to market needs just-in-time, JIT.

They knew that information systems with speed is an integral part in order to be a leaner company. So wherever possible and needed, it was a necessity to get over the bottleneck speed of  physical systems by installing digital systems in order to exchange information in real time as far as possible.

So to that extent, to the extent of available soft technology then, the lean journey at Toyota was already digital.

Today when I heard about Digital-Lean! I thought of cautioning the practitioners not to confuse themselves with it as a jargon. If they do, then the fate could be that the Digital! may get installed but the Lean! may still stay flat and Fat! or rather Fatter! to the extent of the investments made in going  Digital! without correspondingly justified returns (or benefits) over it.

Know that digital was always existing. It's its continual improvement and its development that the today's developed level of Digital! needs to be looked at. It is an integral part of the lean journey anyway.

For instance, going digital in today's context may call for aiding the physical Kanban by E-Kanban wherever possible in support of the physical Kanban (rather than to replace it). The E-Kanban is about the electronic information system about 'when and where to deliver what and how much, etc.' It was earlier existing anyway in terms of a physical card, physical stock management fixtures of needed material and corresponding visuals, etc. Both are supposed to prevent excessive stocks & the resulting wastes!

Another example of going digital in today's context is about the use of RFID tags to sense movements of physical resources during their flow across the supply chain or the value chain.

Or it's about digitally monitoring of the conditions and status of the resources like done using sensors to monitor equipment conditions on-line and using them for decision making (using advanced analytics and statistical analysis of big data) in real time.

But of what use the borrowed 'digital' brain (the digital analytics of data in soft form) is when the real brain 'walks over' (ignores) the real hard data: The data or the hard facts about the probable abnormalities in their seed stage that could be seen, heard, felt, tested (and also tasted) and sensitized in real time?

That's exactly where the caution is.    

                  

                    'Smile-day’ The October 2^nd: Smile!

That's where there's scope for the Digital! to get decimated to be a 'Fad' or 'Flavor of the month', 'Flavor of the week' or 'Flavor of the day', etc. It's much like celebrating such ‘fad-days’ as jargons if people celebrate going Digital! but in reality stay Fat! with problems surrounding them!

Rather than advocating 'fads', a good coach called Sensei in Japanese would handhold, guide and steer the learner to clear off anything that's unsustainable.

So let Digital Lean! evolve and get installed as a matter of strategic need rather than it getting installed to appear modern.

Otherwise it might get easier to digitally smile (as a typical robot would do) while in real world it might still be a physical frown. 

It happened once while I was flying on an airlines! The choice of seat with it's features was a 'window-seat', perfect as it was shown on the computer screen while booking the ticket. But in reality the seat did not have a window at all! 

The last seats normally don't have a window!!

Also read a few relevant blog-posts here-under: Please do consider leaving a comment or consider sharing this post.

Kaizen, even in air!

Digital Corporate Yoga

In a Problem?: No Problem ! Dwell A While !! 
Soon... Waste-to-Eat ! Sea-to-Drink !!
About my first book World-Of-Kaizen

Can-changing-thoughts-change-a-nation
A customer gets what s/he deserves: Shoddy Quality! 
Listen to iceberg of VOC to acquire customers
Make It Simpler, Rest Will Follow 
How To Make A Difference 
Treat Root-causes, Not Symptoms ! 
Do You Cleanup-After-Crisis 
Will It Work Here?  
Some Moron ! Some Great !!! 
That's How Morons Work 
You seem Reasonable if you appear Un-reasonable 
Smart-Moron Who Breaks Your Glass  
WOW Work-Culture: By Telling or Selling 
Can-changing-thoughts-change-a-nation
Ridiculous Poison-culture versus Maverick Kaizen-culture 
Tolerate Once, Twice, Thrice? 
That's how some business partnerships work 
Taken-For-Granted ? You Deserve It !! 
Technology in-place, security dis-placed
IQ-EQ-or-SQ: What-is-more-important?
Customer or Custo-Mer?  
Experienced A Delightful Payment ! 
An Experience of Heart-and-Soul 
Less With More And More Gets Sore 
Should one care for value?  
ABCD of India Shining
Beware Of Political-Presentations 
Do You Cleanup-After-Crisis 
Hoarders Of Filthy Hoardings

Can you do it like the likes of Suzuki and Toyota?

What is common between Maruti-Suzuki and your workplace?

A car every 12.5 seconds!
That’s what Maruti-Suzuki did in the year 2010!
There are plants around the world who may be making one every 1-second!!

What is important is answering the question, whether the corresponding plant are agile and flexible enough to adjust to the change in the rate of the demand from the market.

Yes companies like Suzuki and Toyota do it.
In their parlance this is called as running the plant by adjusting it to the tact time.

TACT is about ‘Time Allocated (by the customer) to Complete the Task’. During the process of fulfilling the customer demand, produce just-in-time (JIT) i.e. nothing more, nor less than what is desired by the customer. While doing so, their employees look for day-to-day problems as opportunities to improve and uproot the causes thereof to prevent their recurrence elsewhere as well.

In fact, not only Suzuki but many other excellent companies run their business learning from the TOYOTA (Kaizen Management) Way!

You can do it too!
You can create similar benefits specific to your business, customers and in fact for all the stakeholders as done by Suzuki and Toyota!!

The Kaizen way¹ of running an organisation is implemented there in a structured way.

Like in Maruti-Suzuki, Kaizen has improved quality and productivity in many organisations like Mahindra, TATA, etc. Kaizen made their processes leaner and faster to deliver in response to the ever-changing and pressing customer demands. It improved efficiency of (man, machine, material and space) resources, pruned  their costs besides achieving near-zero break-down, near-zero defectives and thereby near-zero customer complaint levels. All this is achieved at improved safety levels, reduced pollution and improved employee morale, motivation & involvement.

The journey (be it in manufacturing or service industries, from pin-making to air-lines or from hospitals to hotels) involves three stages.

First, the companies have to benchmark themselves against their past performance.
Then, they have to benchmark themselves against the best practices and companies in the world.
Third, the companies themselves have to become benchmarks worthy of emulation by others.
To achieve such a transformation, what is needed is making a beginning by transforming thoughts that you too can!

Also read a few relevant¹ blog-posts² hereunder: Please do consider leaving a comment or consider sharing this post.

Footnote-¹
Prevention: The Best Cure! ... Is it really so? 
Treat Root-causes, Not Symptoms ! 
You seem Reasonable if you appear Un-reasonable
When Safety Becomes Sorry
How Many Times Do You Wash Hands
Judge If It's Paralysis-By-Analysis

Make checklists your friends 
Can-changing-thoughts-change-nation?
In-big-problem-wear-hats-to-solve-it 
Ridiculous Poison-culture versus Maverick Kaizen-culture 
WOW Work-Culture: By Telling or Selling 

Footnote-² ... Other relevant blogposts
Strategise To Achieve Targets Daily 

Old-Problems, New-Reasons !

Ant Knocks Elephant Down 
Will It Work Here?
IQ-EQ-or-SQ: What-is-more-important 
Talent-Is-Latent: Enable It! 
Judge If It's Paralysis-By-Analysis 
Will It Work Here? 
Suggestions On-Sale, None-To-Buy 
Does recognition really matter 
Who Comes First: Consumer Or Customer ? 
Treat Root-causes, Not Symptoms ! 
ABCD of India Shining 
Do You Ask Right Questions?
Am I 'Short-sighted' or 'Long-sighted'? 

Who Comes First: Consumer Or Customer ? 

Suggestions On-Sale, None-To-Buy

Comprehensive-Strategic-Audits

Soon... Waste-to-Eat ! Sea-to-Drink !!

Do you fill glass 'full' as in picture-1 or fill 'half' as in picture-2 while drinking water?

Some fill it 'half' as in-2 in spite of their need being of 'full' glass. Is it a good practice?

Those who may argue this practice as leading to 'wasted efforts' of having to 'fill it again' may not be wrong. But having filled 'full' glass, 'what-if' suddenly their need changes to 'half' glass for whatever reason?

What do they do in case of such sudden reduction in 'demand' (as in corporate language)? In corporate world the surplus goes in inventory. In case of water above,  some consciously 'empty' it over a sapling. Others put it down the drain into waste.

How many times do such situations result into 'wasted water'?

What would you choose between the situation of 'wasted efforts' and one of 'wasted water'? Don't forget to justify¹ the 'why-you-chose-what' to your ownself.

Do you know that Flat residents (that are 40%), Chawls (10%) & Slums (50%) in Mumbai must shed water consumption down from 50-200 lit/capita/day (lcd) to 50! Else soon they won't have a single drop to drink although may have infinite sea-water around it to see!!!

Similar is the case with 'waste' in every other material including wasted food in plate, if any, that goes into garbage bin.

Do you know that Mumbai generates waste of 450 gcd (grams/capita/day)? It will grow to 600 gcd by year 2020!

What is the solution?

While establishing ²Kaizen-culture to find innovative solutions on a mission to achieve Zero-Waste, we use a Kaizen-technique called ²MISER in order to trigger creativity by asking MISER-questions: Merge, Improvise, Simplify, Eliminate and Reduce.

Can you do MISER in order to eliminate waste and eliminate NVAs so that work becomes Leaner, Easier, Better, Faster but at the same time needing Lesser efforts-n-resources?

In order to preempt use of Merge, Improvise, Simplify and Reduce, MISER technique begins with considering 'elimination' of a resource or a process or an activity.

Eliminate:

Can you eliminate need of a bowl and a bearer's activity by getting a dish self-served directly in the plate? Eliminated bowl reduces consumption of water and wastage of related resources.

Merge:

Can you merge two activities that can be performed by using a single resource? One may use same spoon to consume vegetable as well as dessert.

Improvise:

Can you rearrange placement of buffet food items in such a way that serving becomes easier thereby avoiding wastage due to extra activities to fetch it, spillage due to difficulties in fetching it, if any?

Simplify:

Can you simplify the menu? Now a days hosts boast of a wider variety of menu numbering over a couple of dozen items with funkier names that confuse guests. They forget that too much choice spoils and promotes waste.

Reduce by Reuse-Recover-Recycle (3R):

Can you reduce consumption of resources by 3R-technique? 

Can you reduce size of water glass for instance to half as in picture-3? This will reduce consumption of water mistake-proofingly: The Pokayoke practice as called in Kaizen. This also promotes a component of JIT (Just-In-Time) lean-practice of consuming 'just' the amount needed.

Reuse: Whereall can you 'reuse' instead of 'use-n-throw' practice that generates waste and disposal concerns? After washing clothes, water can be reused for flushing toilets or mopping floor.

Recover: Can you recover whatever possible from a thing before discarding it as garbage and put it for some other use?

Recycle: Can you recycle it? According to the Environment Defense Fund, recycling glass instead of making it from silica sand reduces mining waste by 70%, water use by 50%, and air pollution by 20%.

So What?

"What's new in this blogpost? I have been doing such things! Recycling glass however is not in my hands!!"

If this thought has passed your mind then do force yourself to answer following question:

"Couldn't I have mined at least a couple of more opportunities within self-control to reduce any-waste in any kind of resources in last 24 hours"?: Some saving in water, electricity, fuel, paper, some wasteful activity for self-&/or-others? Nothing at all in spite of these tips? 

If 'NOTHING' then let's be assured, "Nothing at all" is going to be left on this planet!

Footnote-1: No doubt in some situations 'wasted efforts' may outweigh 'wasted water' but generally I prefer the former. The reason is, I can always produce 'efforts' whereas at least as of now no one has succeeded in 'manufacturing water'. Water is a God's creation that needs to be conserved by human efforts!

Footnote-2: Concept from books by Shyam Talawadekar 1) 'World-Of-Kaizen: A Total Quality Culture For Survival and 2) TPM-in-10-days: For Reliable and Just-In-Time Value delivery to Customer.