Cream Rises to the Top

I was working with a team in New Jersey to implement Training Within Industry (TWI) on a critical household cleaner line. Plant leadership saw this as a key element in their strategy to improve overall line performance.

Words Matter

Training and Review is the second spoke on the Wheel of Sustainability. The basis for Training and Review is Training Within Industry, which was developed at the onset of World War II to quickly train inexperienced workers to produce all the necessary armaments and supplies in support of the war effort. It’s one of the reasons the US and its allies won the war.

We Won the Battle but Lost the War

During my corporate career, we identified a critical gap in our safety training system. There wasn’t a good way to ensure traveling engineers, scientists, and technicians were compliant for annual safety training requirements. We had to get everyone immediately compliant and then develop a system for annual recertification.

Lean in Action

I was Lean Champion for the Global Technology group at a ceiling tile manufacturer for six years. During that time, I was responsible to train all new employees in Lean principles and techniques as they joined our group. The goal of this training was to help them understand what we were doing and how we applied Lean to our work. My aim was to generate interest and engagement around Lean. In the early years, things didn’t always go the way I expected.

Attention to Detail

In 2007, I moved my family across country to take a new role as Production Manager for a ceiling tile plant in Oregon. The plant had a strong team-based culture. People genuinely wanted to help each other work in as safe and productive manner as possible. It wasn’t unusual to see the Plant Manager on the factory floor, assisting the technicians with their work or helping them stay safe.

A Wakeup Call

In 2001, I was the Business Unit Manager at a Vinyl Flooring Plant in Pennsylvania. Responsible for the one of four business units on site, I had a unionized workforce of 160 employees, three supervisors, and eight technical staff. My job was to turn the shrinking business around and keep my employees safe and productive.

Let’s See How Things Go

During my tenure as Production Manager at a ceiling tile plant in Oregon, I implemented strict rules around changeovers: No one is allowed in the breakroom during a changeover without Team Manager approval; Everyone is available to help during the changeover; Everyone is at their stations when the line is ready to start up; One Best Way changeover procedures are followed to the letter. No deviations. The procedures were developed by the technicians. There was no reason not to follow them.

Four Value Streams = Four Boards

I reported to the Vice President of Global Technology for a ceiling tile company as Lean Champion. During my tenure, we kicked off our Lean transformation and established four Value Streams: Innovation (R&D), New Product Development, Capital Engineering, and Business and Operations Support. Each Value Stream Director guided efforts to deliver value to the internal and external customers who relied on their critical results.

From Tool Boxes to Tool Stations

In 2011, I was asked to facilitate a changeover reduction Kaizen event at a ceiling tile plant in Florida. Most changeover reduction events have a goal of reducing time by 50%, while maintaining or improving quality and safety. In this case, the team was asked to reduce changeover time by 90%. This would be a challenge for the team and my ability to facilitate them to a solution.

This Stuff Works

At a gummy vitamin manufacturer in Pennsylvania, I was asked to facilitate a team of mechanics responsible for supporting and maintaining the manufacturing operation. They had difficulty keeping their maintenance area compliant with strict food production regulations. Our goal was to develop a system to guarantee compliance, while improving their ability to service their customers.

You’re Never as Good as You Think You Are

Of all the Kaizen events I have facilitated, there is nothing like 3P. It’s the most exciting, energizing, and exhausting way to create breakthroughs with a team. 3P stands for Production Preparation Process. The idea is to design a new product or process with the least amount of waste possible.

It’s Better to Beg Forgiveness than Ask Permission

In 1998, I was invited to Hoogezand, the Netherlands, to help a team make improvements to their ceiling tile production line. Little did I know it would be the longest Kaizen event in my life. I had been to the plant three months before and identified significant changeover time reduction potential. It was time to put my money where my mouth was. In advance of the trip, we identified members of the team and the need for an interpreter. I didn’t speak Dutch and still don’t. We’d have two weeks to work on the line and were to coordinate with the Production Manager any time we needed to shut the line down to work on or test the equipment.

Let It Go

In 2010, Armstrong World Industries emerged from bankruptcy. A minority stake of the company was bought by a private equity firm. This firm knew there were many improvement opportunities and brought in consultants to help create a culture of continuous improvement across the global organization. Their approach was to hold many Kaizen events on a weekly basis, exposing as many people to the principles of Lean as quickly as possible.

Virtual Kaizen Events

For many years, I have led, facilitated, or participated in hundreds of Kaizen events. During those events, people worked together in the same location to solve important problems. Sometimes team members travelled to the location of the event. Other times people weren’t able to travel to the event and the team carried on without identified experts. I loved the interaction and energy of those events, but wondered if there might be a way to hold an event that was as effective as putting people in the same room, but would be less difficult from a travel or logistical perspective.

Call 911

In 2005, a ceilings manufacturing plant on the West Coast was experiencing high downtime rates. I was asked to come to the plant and run a Kaizen event to identify the impact of downtime on the plant.

I was given a small team consisting of four production technicians, two mechanics, one electrician, one engineer, and one supervisor. Our mission wasn’t to solve the specific mechanical or electrical downtime problems, but rather to understand why the response to and recovery from downtime took so long. This was a new concept for the plant and for me, but we felt we were up to the challenge.

Go to Gemba, Even If You Don’t Want To

In 2019, I was asked to facilitate the annual Value Stream Mapping (strategic planning) event for a leading consumer brands manufacturer at their facility in Central Pennsylvania. I had facilitated their event the prior year and it was our intent to build on the prior results and drive their continuous improvement culture forward during the event.

Best Event Ever

I was the Lean Champion for Armstrong World Industries for six years. My responsibility was to guide the organization to a continuous improvement mindset in all of their activities. I had no direct reports and reported to the Executive Vice President of Global Technology. When we kicked off our Lean transformation, most in the organization felt we were implementing the “flavor of the week” and weren’t ready to commit to changing their habits.

Macon Progress

Once upon a time in 1998, I helped a team in Macon Georgia improve the reliability and safety of one of their production lines. The work was exciting, the team was enthusiastic, and we were making breakthroughs beyond what I ever imagined could happen. Something was missing, however. For some reason our sponsor, the Business Unit Manager, never came out to the line to see what we were doing. Although the team didn’t seem to mind, it really bothered me. After all, we were doing things so quickly and effectively, and solving so many problems that others weren’t able to solve, I wondered why he didn’t appear to be interested in our progress. If you know me, you could predict I would do something about it. And, I wouldn’t be subtle about it.

Gemba Walks

For those unfamiliar with the term, Gemba means “the real place, the place where the work is done.” A Gemba walk therefore means that you are going to walk through the real place and assess the work being done there. I tweak it a bit to mean, “assess the health of the operating system.” This sounds like an audit, and it is. For many companies, the idea of the Gemba walk is to take people out of their offices and walk through the process with their people. It’s not always the most comfortable thing for people to do. If done well, it can be extremely impactful. If not done well, it becomes a big waste of time.

Color Coded Badges

The Pilot Plant at Armstrong World Industries, a global ceiling tile manufacturer, has tons of operating equipment designed to allow technicians, engineers, and scientists to try out their ideas and experiment in their efforts to create new processes and products. One of the areas in the Pilot Plant that gets the most use is the wood shop. Containing over 50 separate pieces of equipment, much of it requiring skills to operate it safely.

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