Stories of Leadership, Lean, and Learning
I started my career as an industrial engineer for Thomasville Furniture in North Carolina. My initial responsibilities included warehouse barcoding support and veneer plant projects. For the warehouse, I had to learn how barcodes were used to inventory, ship, and receive finished furniture from the various plants in the network. In the veneer plant, I was to conduct time and work studies and also identify improvement projects.
Read MoreI met Cody at a conference in December. We got along so well he invited me to visit his new company in Florida. Before the conference was over, he asked for six copies of my book, “The Wheel of Sustainability.” He wanted a copy for every member of his leadership team. Cody told me he was going to require them to read it before my visit. I was happy to share my books, as no one had shown so much interest in them before. I never could have imagined the level of interest and enthusiasm of one person in particular.
Read MoreI met Andrew Koenig, the CEO of CITY Furniture, at a virtual Lean conference during the pandemic. We immediately hit it off, and he invited me to help strengthen the Kaizen culture at his company.
For two years, I facilitated Kaizen events on a monthly basis. It never ceased to amaze me at the number of improvements and breakthroughs that could be accomplished in a company that has been living Lean and continuous improvement for many years. More than that, the energy of team members was inspiring and infectious. I was warmly greeted by associates on every trip and many of them proudly showed off prior improvements and how they were sustaining the gains from our Kaizen events.
Read MoreI have experienced two mergers/joint ventures in my corporate career at Armstrong. The first one was a ceiling grid venture between Worthington Industries and Armstrong. It was extremely positive and productive and is still doing well to this day. The second one was a ceramic tile venture between Armstrong’s American Olean Tile and Dal-Tile, based out of Dallas Texas. This one didn’t go nearly as well. I learned many lessons from the Dal-Tile experience, mainly about my ability to survive.
Read MoreI worked as a supervisor in a small ceiling grid plant for Armstrong in Franklin Park Illinois. In my first year there, Armstrong and Worthington Industries created a joint venture to leverage each other’s strengths and grow the business. I was offered the role of industrial engineering manager at the plant in Sparrows Point Maryland. The plant in Franklin Park was going to be closed.
Read MoreMidway through my corporate career, I was a senior industrial engineer at Armstrong World Industries. I spent most of my time providing support to our many manufacturing facilities all over the world. I have always been fascinated by manufacturing and it never ceases to amaze me how good (and bad) decisions can immediately impact performance.
Read MoreDuring my career, I have been fortunate to have worked all over the world. I was brought up as a “tourist.” Whenever I traveled with my family, we would do everything possible to see the sights and learn the history of the region we were visiting. Because of this, I naturally enjoyed my business travel and did my best to explore and experience the culture of any location I visited.
Read MoreMy first Kaizen event with a new client in Oregon came as result of my site visit the month before. We were going to apply 5S to an area of their plant that was well behind budget. During my visit, I noticed that although prior efforts had been made to improve organization, they hadn’t stuck. With the appropriate use of Lean principles and the Wheel of Sustainability, I felt I could help them get back on track.
Read MoreHave you ever had a meeting where it seems like nothing was accomplished? Is every meeting this way for you? Do your meetings start late? I have facilitated hundreds of meetings and Kaizen events and have learned over the years these five key tips to an effective meeting.
Read MoreLast year, Dave, a network connection, reached out to me to see if I could help him in his continuous improvement journey. His wife had worked with me at Armstrong, and one evening he was talking with her about some of his frustrations at work. She said, “If you want to get the right help, call Adam. He is tenacious and won’t let you or your team fail.”
Read MoreEarlier this year, I received an email from someone I never met, asking about my approach to 5S – organizing a workspace to improve safety and productivity. He heard about me from another location in his company, who I helped six months earlier. Later that week, we were in a Zoom meeting, and he invited me to his factory in Oregon to see if I could help jump-start their 5S efforts.
Read MoreI love giving out little trinkets. It’s fun to see people’s reactions to the things I hand out – coins, ninjas, books. This story is about ninjas.
Read MoreWhen you are in the heat of battle, you don’t realize the toll it’s taking on your health. I was the business unit manager for a vinyl flooring operation for Armstrong World Industries for two years. During that time, we were in a continual state of downsizing. This didn’t help the relationship with our union. It seemed like everything we tried to do to improve safety, cost, quality, or customer service was met with resistance.
Read MoreThere is always a compromise that can be made. You just must know what you want and figure out how it will benefit both parties. I have been negotiating since as far back as I remember. Sometimes it was bedtime, eating my dinner, or putting off homework to go outside and play. Parents don’t typically cherish those negotiations and kids rarely win (at least I didn’t most of the time).
Read MoreI was working at the American Olean ceramic tile facility in Olean, New York as the Industrial Engineering manager when we merged with Dal-Tile. I was offered a position as an industrial engineer at the corporate offices in Dallas, Texas. I was very impressed with the manager who I was going to report to, so I took the opportunity and moved my family south.
Read MoreIn the 1980’s, Thomasville Furniture was the market leader in high-end furniture. They were extremely focused on process improvement in all areas of the business. I worked on a staff of industrial engineers. Each of us supported one or more of the many manufacturing facilities. We were tasked with finding ways to improve safety, quality, productivity, and customer service.
Read MoreAdmit it. After reading the title of this story, some of you are hearing the famous Lionel Richie song in your head. This story isn’t about that, but rather it concerns a challenging Kaizen event I recently facilitated for CITY Furniture. The business problem we were trying to solve was a series of computer programs that ran after all showrooms closed each evening. There was a period of time where no revenue could be generated through their e-commerce website, until all programs completed their reconciliations. Our goal was to cut the time by 75%, so that we could free up overnight revenue generation.
Read MoreArmstrong World Industries kicked off their Lean journey in 2010. They put a lot of effort into building a culture of Kaizen across their 22 manufacturing locations worldwide. I was sent to many facilities to assist.
Read MoreI graduated from Virginia Tech and went to work as a corporate industrial engineer for Thomasville Furniture in North Carolina. Harriet was my first mentor. She was working on a project to improve the productivity of one of our bedroom furniture manufacturing facilities.
Read MoreI was facilitating a Kaizen event for a large furniture retailer in Florida. They offer many services that set them apart from their competitors. They have a nice sales and service advantage and impressive customer loyalty. The Kaizen topic we were working on was the use of replacement parts in their process. Our goal was to reduce the amount of replacement parts needed.
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