Build it wrong

Have you ever launched a production line only to start making bad parts instantly?

Have you ever launched a production line with a horrible PPM ranking after weeks of meticulous planning?




Product development is complex and demands a process of it’s own to ensure critical elements are considered and implemented. I could –and others have written, volumes on this topic, but today I want to focus and share a tried and true method of bullet-proofing your manufacturing line.


There is actually a trick.

Sure..

• You think you know how to assemble that part.
• You think you’re a good communicator and trainer to teach others how to put it together.
• You think you’ve balanced the line such that every person is done with their assigned tasks in 12 seconds.

You think.

Before you’re finished with designing fixtures and equipment for the production line and certainly well before you even consider a run at rate evaluation, host a ‘build it wrong’ day.

That’s right. Dare your team* to build the part wrong.

HOW TO:
*Collect a diverse group consisting of engineers, managers, team leaders, operators, and maybe even your staff assistant and assign them a ‘station’. At each 'station', provide them all the parts they'd need at that defined ‘station’ along with a few tools both necessary and completely useless, then tell them to put it together.

ie: say: "put this together", and walk away.

That’s right, provide no other instruction, no other words.

In addition, create a special ‘station’ where you have all the parts for the assembly and have someone try to assemble the whole thing by themselves (again without any instruction what so ever).


WHAT YOU’LL DISCOVER:
• Poke Yokes you’ll need to create; both design and process

• Operator instruction noteables

• Product design changes necessary to eliminate possible mis-builds

• Process steps needed

• Special tools required

• Ergonomic changes to the station including fixtures and tools necessary


THE BIGGEST LESSON?

You’ll discover what you don’t yet know.

Are you boring?

One of my earliest experiences with a project team was in the development of a hinge that would be unlike any hinge we’d ever created. This particular design element was critical to the rest of the product and had to be tackled early as it would drive the aesthetic and thereby likely the function of our product solution.

I decided I didn’t have to figure this out all by myself and challenged my team with a whacky benchmarking assignment they’d have to complete on their own time outside of work. Initially there wasn’t much movement around the table nor hearty acceptance of the proposal but as the idea swam inside of the heads of each colleague you could see creativity take root.

Two days later, we met again. Every one had done their homework. Every one had bought their hinge of choice for a show and tell, ideas spouting from each inspired to a better solution as we went around the room.

One thing was clear: they were hungry for inspiration, expectation, and a challenge.

How are you challenging your team every day?

How are you challenging yourself?

update: I was catching up on my NPR listening and found this snipit on motivation in the workplace. Give it a listen (short & sweet):

It's not my job

A month ago Thanksgiving, I talked about being thankful to your colleagues. As the week of Christmas has arrived, I am thinking about what and how you give in your organization.

What are you giving back to your organization?

Ideally, your teams are made up of diverse skills and viewpoints complimenting each other on how they interact and what they bring to the table. Your teams are confident enough to counter view points for creative discussion leading to creative solutions.

We all have our role. We all have our job.

Having our role also means that there are roles that don’t belong to us; tasks and responsibilities that don’t fall under our umbrella – tasks left to others.. jobs that aren't ours.

Do you ever do things that aren’t directly assigned to you? Of course we all have to mindful of our immediate and long-term responsibilities to ensure our work is getting done without being overworked ourselves, but I’d like to explore what happens when we give of ourselves fully at work.

Let’s starting with making a list of things that we could give:

• Pick up any trash you come across that’s the size of a dime or larger on the floor

• Help a colleague pick up something that accidentally spilled

• Walk a strong pace to get to your destination quicker – to finish quicker

• Smile and greet every person you encounter in your office

• Listen respectfully to every person you interact with in your office

• Help someone do their job if you have idle time

• Research and brainstorm on products, services, or just plain ideas that will help your company to do more.

• Contribute in discussion at meetings

• Prepare for meetings you’ll attend

• Finish your work when you’ve committed to finishing it

• Continuously think of ways you can do your job better

• Continuously think of ways your company can service its clients better

• Choose to share the positive verses complaining or dwelling on the past

• Support the team decision and make it successful even if you disagree with the method (within moral limits obviously)

• Go the extra step, put on the finishing touches, and do a little more proudly to delight your clients (or the colleague you’re delivering to)

• Be proud of what you deliver

• Understand the ‘why’ of decisions so you can support them fully

Wouldn’t you like someone who did all these things to work for you?

What more would you add to this list?

Sustainability in Leadership

There’s a lot of talk about sustainability of the planet, our energy sources, our households, our offices, and our products, but what about the sustainability of our leaders? What about the sustainability of your leadership?

What is your environmental impact on others?

Our words and actions are powerful in how others respond to us and how they perform their work. As a leader you are responsible for motivating your teams and moving your business in a positive direction.

The cost of uninspiring leaders is hard to measure as external factors are easy to point to as possible root causes to long launch cycles, lack-luster ideas, high PPM, low moral, and head butting between groups. As humans we’re wired to want to do good work and to be successful. Our personal pride runs deeper than any corporate directive. Consider how productive one might be however if your leadership combined with the corporate directive aligned with the personal motives of your team.

Just for kicks, let’s compare our needs and goals relative to plants:

P L A N T S			P E O P L E
Grow and get bigger			We want to grow, improve, succeed
Need sunlight			Want to prosper,
			Be seen as successful,
			Want to shine
Need water			Need encouragement
			Need feedback
			Garner respect
			Need to be empowered
Need support			Work better in teams
			Need a leader’s protection
Need fertilizer			Need training
			Want to learn new skills
			Sometimes need guidance

Like plants our needs are simple and just like plants we can still find a way to exist without enough water, sunlight, and support; the result is similar: smaller yield, less stunning product, lower functioning, and more issues.

How are you nurturing the environment around you?

We give water to our teams by providing encouragement and feedback in a way to help them do better in the future. We support by matching our employee’s skills to the task and partner complimenting skill sets. Through empowering others and setting them up to succeed, we also enable personal responsibility and ownership to succeed.

We support our teams by running interference between them and upper management, justifying work loads, timing needs, and effort to protect them from unneeded stress. I once took the heat for a two day delay in a program because an experienced and highly respected designer made a simple mistake causing a week’s worth of effort to be trashed and all designs to require rework. We were lucky in that the mistake was caught by the team. The designer knew the stakes were high and volunteered to work overtime squeezing seven days lost into two. Did my upper leadership need to know the name of this individual and their oversight or could the team (namely me) take the hit?

By protecting this individual, his reputation was not tarnished, his personal stress level did not rise from leadership pressure, and the team felt empowered by catching and readily fixing the issue. At the end all that was remembered was how well our team performed because our product launched successfully first pass.

What is your leadership story?

How did you nurture your team today?

Originally posted by me on http://linked2leadership.com/2009/05/10/sustainability-in-leadership/ May 10th, 2009.