Press clippings

May 5 2018

French TV Show Blames Nurse Suicides On “Lean Management” In Hospitals

On September 7, 2017, France2’s Envoyé Spécial (“Special Correspondent”) had a feature about a suicide epidemic among nurses at French public hospitals and blamed it on the adoption of management practices from the private sector, and singled out “Lean Management” as a method from the car industry that resulted in treating patients like cars and nurses like assembly line workers. It went on to explain that it was Ford’s system “from the 1930s,” dressed up by Toyota with a few Japanese words.

Besides the reporters’ inability to get basic facts — Ford’s system is not from the 1930s and Toyota’s is not a copy of it — I don’t recognize here any of the approaches I have heard from colleagues involved in health care, like Mark Graban, Pascal Dennis, or Katie Anderson, and it doesn’t match my experience as a patient in a healthcare network that has had an active Lean program for four years. Mostly, what I have noticed is less waiting when I show up for appointments, friendlier staff, and enhanced online services, including communications with doctors.

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Feb 18 2018

Toyota’s Way Changed the World’s Factories. Now the Retool | K. Buckland & N. Sano | Bloomberg

Shigeki Tomoyama

“The automaker last month created a single group, staffed with 200 employees, to manage the Toyota Production System, centralizing a function that was spread out through the organization. Their task is to evaluate how core concepts like kaizen, or continuous improvement, can be applied to new businesses that include car sharing and consumer robots. The person in charge is 59-year-old Shigeki Tomoyama, a career Toyota executive who wields a tablet computer during events, making him look more like a Silicon Valley software engineer than a car guy. […] Akio Toyoda says the automaker his grandfather founded eight decades ago needs to move faster to keep up with the likes of Google and Uber Technologies Inc. […] In the last two years, Toyota has opened a Silicon Valley research center”

Source: Bloomberg Technology

Michel Baudin‘s comments: The article includes a group photo of the original Gazoo group from 1997 that includes both Tomoyama and current Toyota CEO Akio Toyoda:

Gazoo is an internet portal created by Toyota that is in sharp contrast with the brochureware websites of other automakers, featuring, among other things, articles about classic cars, used cars, road trips in Japan, and entertainment devices for kids during drives. This article is the first reference to Gazoo that I have seen in the American press. It’s unfortunate because Gazoo has been online since 2000 and is an approach to car marketing that deserves attention.

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Feb 5 2018

Countries Don’t Have Production Systems, Companies Do

Kobe Steel CEO apologizing (10/2017)

“Companies Everywhere Copied Japanese Manufacturing. Now the Model Is Cracking. Concepts celebrated in business publications worldwide have been tarnished by a string of scandals.

Japan’s reputation for flawless manufacturing quality and efficiency transformed the country’s postwar economy, changed business practices worldwide and spawned a library’s worth of management manuals and business advice books. Now, the model is cracking.

Kobe Steel Ltd., Mitsubishi Materials Corp., and Subaru Corp. have all admitted in recent months to manipulating quality inspections, though all say no safety problems emerged. Takata Corp. declared bankruptcy last year after admitting to supplying more than 50 million defective vehicle airbags in the U.S. Mitsubishi Motors Corp. has admitted covering up vehicle faults and falsifying fuel-economy data.”

Sourced from The Wall Street Journal

Michel Baudin‘s comments: What does the Volkswagen diesel emission scandal say about eyeglass lenses and telescopes made by Zeiss or A320s assembled by Airbus in Hamburg? Nothing. Factories for these companies are all located in the same country but a lapse by one is just that, and the Wall Street Journal did not publish articles suggesting that it made a statement about German industry as a whole. When it comes to Japan, however, this is exactly what they are doing with this article, assuming there is such a thing as “Japanese manufacturing,” which is blemished by the misbehavior of any Japanese company.

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Jan 24 2018

Why It Makes Sense (Sometimes) to Start With Hoshin Kanri | Dan Markovitz | IndustryWeek

“Strategy deployment is a powerful way to get the leadership team involved in the lean journey.For a long time, I’ve been dismissive of organizations that want to start their lean journeys with hoshin kanri, (also known as strategy deployment). When you’ve got a company where people are not engaged (at best) or suspicious of management (at worst), it seems to me that getting people involved in everyday improvement to make their jobs easier is a better place to start.[…] Until now. Recently, my colleague and friend Katie Anderson pointed out something I’ve completely missed: that strategy deployment is a powerful way to get the leadership team involved in the lean journey.”

Sourced through IndustryWeek

Michel Baudin‘s comments: As I have great respect for both Dan Markovitz and Katie Anderson, I have to paraphrase Judge Haller from My Cousin Vinny, “That is a lucid, intelligent, well thought-out argument… Overruled.”

The flaw I see in Dan’s argument is that it only addresses employee engagement, which isn’t the only reason to start with local, tactical shop-floor projects with both technical and managerial content. In an organization that is just starting on its journey, the successful initial projects are most commonly setup time reduction or cell conversion of a process segment. Besides engaging employees, they also produce tangible improvements, develop technical and managerial skills, and let leaders emerge.

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Nov 24 2017

Now It’s Humans Assisting Robots | Sheelah Kolhatkar | The New Yorker

Steelcase ology

“[…]As a zone leader, Stinson is responsible for about fifteen employees on a section of the production line that makes parts for Steelcase’s Ology series—height-adjustable tables built for the standing-desk craze. Until last year, the plant workers had to consult a long list of steps, taking pains to remove the correct parts out of a cart filled with variously sized bolts and screws and pins and to insert each one in the correct hole and in the correct order. Now computerized workstations, called ‘vision tables,’ dictate, step by step, how workers are to assemble a piece of furniture. The process is virtually mistake-proof: the system won’t let the workers proceed if a step isn’t completed correctly. We stood behind a young woman wearing a polo shirt and Lycra shorts, with a long blond ponytail. When a step was completed, a light turned on above the next required part, accompanied by a beep-beep-whoosh sound. A scanner overhead tracked everything as it was happening, beaming the data it collected to unseen engineers with iPads.[…] ”

Sourced through The New Yorker

Michel Baudin‘s comments: This is excerpted from a long article entitled Welcoming Our New Robot Overlords, from the 10/23/2017 issue of The New Yorker that caught my attention because it’s not about robots and it seems to be in the same spirit as Omron’s Digital Yatai back in 2002: using technology to eliminate hesitation and to mistake-proof operations that are too long or have too many variants to allow operators to go “on automatic” while performing them.

When repeating the same 60 seconds of work 400 times in a shift, operators quickly develop the ability to execute rapidly and accurately with their minds elsewhere. If on the other hand, the takt time is 20 minutes or the work is customized for every unit, the work requires the operators’ undivided, conscious attention and their productivity is increased by systems like the vision tables described in the article, that prompt them for every step and validate its completion.

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Nov 7 2017

More Sophisticated Graphics In Today’s New York Times

Mass shootings versus number of guns by country
Mass shootings versus guns per capita by country

“When the world looks at the United States, it sees a land of exceptions […] But why, they ask, does it experience so many mass shootings?[…] Perhaps, some speculate, it is because American society is unusually violent. Or its racial divisions have frayed the bonds of society. Or its citizens lack proper mental care under a health care system that draws frequent derision abroad. These explanations share one thing in common: Though seemingly sensible, all have been debunked by research on shootings elsewhere in the world. Instead, an ever-growing body of research consistently reaches the same conclusion. The only variable that can explain the high rate of mass shootings in America is its astronomical number of guns.”

The source for both charts is Adam Lankford from the University of Alabama. The charts Include countries with more than 10 million people and at least one mass public shooting with four or more victims.

Sourced from The New York Times

Michel Baudin‘s comments: Six months ago, I was bemoaning the absence of scatterplots in business analytics and more recently complimenting the New York Times for the sophistication of its graphics. Manufacturing professionals should not be shy about using scatterplots, as they have learned to do in Middle School. Here, they are used to highlight outliers, which isn’t the most common application. What this article — and these charts — show is how the tool can be used not just to solve technical problems but to inform a political debate as well.-

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