Uncategorized – Frank Rzeznikiewicz

Category: Uncategorized

September 1, 2022

Five S Implementation

The 5S initiative is one of the most difficult to accomplish in your lean journey. The efforts to sort, simplify, sweep, standardize and sustain are the backbone of lean. Many companies roll safety as the 6th S, but in reality that is a mistake. 5S is about the lean manufacturing of business. For businesses to treat the safety of employees on the same plane as lean is a critical mistake. In the hierarchy of business and employee needs, employee safety is the most critical and far more important than efficiency and is the baseline of the hierarchy. The emphasis on the 5S is overlooked and considered by many to have aspects that are optional and not necessary for productivity improvements. Nothing could be farther from the truth.

Sorting is necessary for several reasons. First a sorted facility reduces inventory waste, eliminate the use of un-standardized tools or parts, and eliminates confusion to employees who are at different training levels. It also increases usable space by the elimination of storage for unnecessary items, obsolete tooling, and duplicate materials. Having the correct tools visually noticeable in each workplace allows both the operators and supervisors to realize any shortages that may exist. If you look at effective assembly operations, tools are placed in the proper places before, after, and during production. Have you ever had the home project and did not return the hammer to the proper place at the end of a project? Then in a couple of months when the next project is started you floundered to find where you left that hammer. The same is said for the wrench on an assembly line. After the daily production is complete, if an operator leaves the wrench in an undesignated location, they will have trouble starting the next day’s production on time. Therefore, efficiencies are dwindled from their optimum. Communication between shifts and workers becomes more effective in a well sorted environment and much of the extraneous discussions and frustrations disappear as everything is where it should be located. Finally, a poorly sorted operation effects the quality of product. Tool substitutions are minimized as all the proper tools are always available to everyone. The application of any incorrect parts or subassemblies are eliminated.

Simplifying the operations are key to the lean process. This effort also reduces inventory as designers attempt to use common hardware that is readily on hand. This prevents special orders for unnecessary products. This also eliminates waste due to difficulty in using unique items and improves quality as options for misapplication become more limited. But the simplification goes further than design. It includes the arrangement of the workspace and encompasses shadow boxing tools and standardizing the best tools for the job. The development of simple jigs and fixtures improves the quality of product as a standard method of locating features is in place. Jigs can be designed with the same basics and mere detail changeovers accommodate mixed model production. As a manager, we should also drive the organization to the simplest functionality by reviewing each step of the operations with engineering, operations and quality concurrently. Do not merely accept the design from research and development as seldom is efficiency and productivity taken into account.

Sweep or shine is essential for several reasons. First and foremast is ensures a safer workplace. The cluttered workplace is one that is doomed for trips and falls. Clean and bright workplaces have a psychological effect on workers that is positive and is one where we are proud to employ ourselves. The lack of lighting can lead to poor morale and inefficient work. Shine can also assure that tools are in the proper condition for usage at all times. The lack of lighting also allows undetected visual defects and therefore the bright and shiny workplace is less apt to produce and ship nonconforming hardware. I painted all my machines white in a company. Initially, the thought of white machines that remove metal was frowned upon because it was not sustainable. As each machine showed a leak, the leak was fixed to prevent the need to repaint. That triggered an improved TPM program which reduced downtime by 21%.

The most difficult is the standardization of work. This effort integrates the sort, weep and shine and simplifying efforts. It ensures conditions do not deteriorate to the former state and facilitates the implementation of the aforementioned. The standardization of work ensures that work is performed the same way time after time and integrates an improved quality and predicable delivery plan. It is difficult to create the standardization of work and it is very time consuming. You must segment your workplace into sub-sections so that smaller successes can be declared and celebrated. It is essential that the format for the standardization is easy to implement and that any software you use is ready to use for its purpose. Do not use ad hoc programs as the documentation and implementation is difficult and strangling the organization with complicated programs will exhaust personnel. Eventually, your standard work will allow you to predict how many people are needed to attain takt time for work cells and will assist in allocation of resources necessary to attain customer commitments.

Making a habit of properly maintaining correct procedures and installing the discipline to regress requires that all personnel including management pay attention to detail. The consequences of not allowing employees to correct standard work when needed, to clean, sort, straighten the workplace, and allowing an environment of sustainment will deter any advancement of the lean systems your put in place. It will evolve a culture where employees will consider your journey as another program that went to the wayside and will make any revitalization of the effort more difficult.

June 4, 2022

Reflections on Successful Leadership

As we walk the path of guiding organizations to success, we need to question whether we are successful. Too many leaders are greatness in their own minds and they measure success merely by business metrics. As they progress down their strategic plan, one day they are woken to realize that their workforce in disengaged, reacting only to commands, lack empowerment, seek others to represent them, and are disillusioned with what success resembles. That leader will first defend their actions and accuse the workforce of being lazy, not motivated, and simply a reflection of a poor work ethic that is a culture problem. They will increase demands and employees will react slower and with resentment. Have you ever worked for a leader like this? We all have. They end up failing and hurting companies that take years to recover. They are the egomaniacs of the world. Every other sentence is “I”. They may not have started out this way but have slipped into a false sense of self-worth and accomplishment.
There are ways to stay away from the slide as a leader. You are nothing without your empowered, engaged workforce. You cannot lead a defeated organization using the same tactics that defeated them. Below is listed ways to avoid slipping into the trap.

1. Communicate every day with someone in your workforce. A regular conversation with the people from all levels of the workforce is necessary to keep a pulse on your organization. The continued communication develops relationships and allows you to receive feedback in a real time manner.

2. Don’t dismiss criticism. There are disgruntled employees everywhere but you cannot merely dismiss complaints as those of a poor employee. There is usually a shred of truth in every complaint or statement. It may be exaggerated and at times or may be something stated with an ulterior motive, but examine what is said. Do not over-react to every comment but place some credence in it and examine if what is told you is the truth.

3. Hold regular multiple group meetings. All Hands meetings should occur monthly, sub-groups should meet weekly and work groups should have a meeting format on a daily basis. While the finance world will measure this as indirect labor charging that shows a loss, the resultants for improved productivity will far exceed those small losses. There is no format for everyone. Some people will not speak out in a large group and some will feel secure in those groups and give constructive feedback. Small groups can also be intimidating for some people and there are work group clicks that will stop some from speaking up. Finally, hold regular skip level meetings on a regular basis. They should be a minimum of quarterly intervals. Skip levels eliminate the presence and intervention of middle management. People will speak more freely in these meetings and you will receive different feedback. Caution: Do not overreact or make promises to fix problems in these meetings. Doing so will result in group leaders and middle management feeling betrayed. You are there to gather feedback, describe your vision and strategic plan, and create list to investigate.

4. Be honest, loyal, ethical, and have principles each and every day. Do not deceive your workforce. There are always business situations that do not allow you to unveil everything to the entire workforce but you can merely state “I cannot comment on that now”, “We have not made final decisions regarding that matter and when we do we can discuss it”, “I understand your concerns and when we have answers to those we will discuss at the next meeting” etc. Do not lie. Your workforce will lose your trust and everything that is discussed at meetings will be merely dismissed as a possible misrepresentation.

5. Walk the walk of you employees. Walk their job with them for an hour every year. Learn what their job is and understand their challenges. While you walk their job with them, realize they are people that work to live. They have families, children, parents, schooling issues, financial burdens etc. Talk to them as a human being and a leader. Nothing makes someone feel valued more than when you walk the floor and can say, “John, how is the boy’s baseball team doing?” Mary, how is the daughter’s gymnastics coming?”, “Harry, how is mom doing”. It may seem impossible but you can easily take 250 hours a year and dedicate it to this activity.

6. Protect your workforce. Watch and listen for unreasonable management and team leaders. Pay attention to safety and join a safety committee. Realize ergonomic challenges. Prove to people you care because you do care and react quickly to safety issues. People are your greatest asset and protect them like the jewels they are to the organization

Be a leader that people embrace. Reward, recognize their achievements, thank them and show them they are important. If you do not understand or agree with most of these items, you are on a path to failure. Don’t delegate these items to others-walk the walk each and every day.

December 23, 2020

Analyze, Standardize and Simplify

Whether you are in a supermarket, bank, hotel, car rental facility, or any service industry you may have noticed the lack of performing any work that is not efficient. When there are issues that are not standard, people stumble through the process and virtually annoy the customer. The same is true in all facets of work life and the answer is the same. There is no standard work for performing the operations, a lack or training in the unusual circumstances, and the lack of proper management planning. In many articles and books, the focus on value stream mapping and standard work is manufacturing. In reality, it affects our entire culture and lives. Little is done to assure that processes are defined and standard work created for variations to those processes. If a price change needs to occur in the supermarket or if the use of an alternate fixture in manufacturing occurs, the results are the same. The cashier should have an easy step by step menu on how to correct minor variations in processing a customer and the operator should have standard work and work arounds for the unusual cases.
Where do you begin? Take the time to hold an event and create a value stream map. Within the map flow all the work-arounds and unusual processes. Display the rework loops to a normal process and the turn backs to both internal and external customers. Assure the value stream displays reality and not opinions or the engineered belief of the process. When the map is complete, review it with everyone and assure every element in the process is addressed.
Next, compare the process analysis to reality. Witness different people performing the process on all available shifts. The variation to the process will allow you to observe the lack of clarity in your processes and the variations that can occur. Take notes and communicate with people to get input about the variations. Compile your observations and review with your entire team to determine the correct method of processing. Then recreate your future state standard work to the optimum process.
When creating the future standard work, you must consistently “step out of the box” to review if certain current steps are necessary and whether simplification of operations can occur. Always look into a leaner mentality. There is always a way of eliminating waste. Whether is simplified operations, reduction of movement, elimination of non-value added steps, or simply reducing the variation of processes by mistake proofing them, a streamlined process is the only way to operate. In the service industry, there tends to be a focus on arduous step by step intervention. For instance, checking into a hotel, standing in line and waiting can be annoying. Why isn’t there a kiosk that with the swipe of your credit card your reservation is verified and simple questions are asked on preferred accommodations (i.e. King, Queen, Floor Preference, etc.) and number of keys required is entered and the keys with the room number drop into a tray? While not all travelers may prefer that type of service, an option can lessen the lines and wait for those that do want the face to face intervention. When the waitress sits you at the table, why isn’t there a portable tablet that allows you to enter drinks and appetizers that would allow someone requiring quick service to place an order in simple easy steps? This would reduce the wait time for a waiter/waitress. Many companies are beginning to make changes and those that do make those changes are grabbing market share from others. Some medical businesses are beginning to make the change through kiosks, defined stations for check in, and lines on the floor to eliminate confusion. These all are ways to simplify the experience and eliminate unnecessary steps and costs.
Look at your service, processes and methods of operation and determine where to start. Takes small bites of you process into consideration. While manufacturing is focused on lean processes, do not believe that it is only for those types of businesses. Make your business unique and streamline it through standardization. These changes do not require a massive effort but if you do not begin the process, you may be left behind in the market place.

February 7, 2020

The Journey Begins

The challenge of starting systemic productivity improvements in a facility and knowing where to start is not academically taught and is usually based on experience. Consultants my give you a program that it so large to implement that success is limited. When you decide that your company has used all the conventional methods to improve efficiency and productivity and they have “block and tackled” every avenue to increase outputs, what do you do? The answers are not simple but they all follow the same theme.

The first step is stop and look. Let the processes flow normally and look for two types of changes, systemic and points of production. The first type of change is systemic and you must form a three to five year plan and an initial plan. First observe the flow and identify evident systemic gaps. It could be a process, an element of production (i.e. safety, quality), a product flow, the placement of an order, or procurement. The second type of change is individual points of production changes. You must find three to four small areas of change that will be the example for the changes in the future. You must remember that you probably have not changed the culture of the facility and have not communicated well with your workforce. You need to pull ideas out of employee’s heads for understanding their efficiency roadblocks. These small areas of change are critical for changing the culture to one where employees will be your consultants. The quickness and sincerity of your responses to ideas they give you is critical. If you want to improve, you have a wealth of information in your workforce that will provide you success and them with a sense of accomplishment.

Form a plan that employs the overall systemic changes you want in the long term. Take that overall plan and divide it into smaller sequential system changes that will align your vision and your overall systemic change plan. These systemic changes must be ones that are smaller in nature when you begin your journey to change a company. They must be ones that will improve the processes but also ones that have minimal negative side effects within the workforce. You may want to relocate a department to increase flow. You may want to separate processes and remove production delays by segregating workflows to their proper elements.

The first changes you make must be reviewed with your leadership team to attain both consensus and comradely. After that has been accomplished, you must present your long-term systemic change plan and the initial changes to your entire population to explain how your vision and strategic plan align themselves. Remember to speak with anyone that may perceive your changes as affecting them negatively. The worst tactic is to present material to all your people at a group meeting and someone that is affected being advised at the same time. You need to assure that people are not being surprised and not feeling that you did not speak to them to get their inputs. They may not always agree but they will at least understand you motives and expectations. You can never over communicate. Once you have presented the material to all, act on it. Failure to do what you say will create a perception that management does not do what they say they are going to do.

Creating the correct change path is vital. You need to create a few small changes that will support the overall long-term plan. Remember that any huge change usually takes a long time and your employees are watching to see if things are really going to ascend to a better The challenge of starting systemic productivity improvements in a facility and knowing where to start is not academically taught and is usually based on experience. Consultants my give you a program that it so large to implement that success is limited. When you decide that your company has used all the conventional methods to improve efficiency and productivity and they have “block and tackled” every avenue to increase outputs, what do you do? The answers are not simple but they are all follow the same theme.

In the points of production changes, you must address a process improvement project for each major sector of your business. These should be the result of interviewing the people and finding out parts of their job that are troublesome and hindering productivity. They may not be what you think is of the utmost importance but they are the issues that concern your workforce. Accomplishing these is vital to your changing the overall business and a significant step in changing the culture of your organization.

You must remember that you have probably forced as much change through the organization that is possible by your powering the organization forward. You now must take a different tact. Embrace the workforce for ideas and act on them. Regard safety as not only a benefit to the people and company, but realize an unsafe environment will create inefficiencies. As you work down this strategic path you will enact your vision to actualization and display the correct atmosphere and culture.

Finally it is critical not to make this a one-time event. Continue this philosophy and continue to take small strides that will change the overall effectivity of the business. Embrace your workforce, communicate with them continually, and improve the business one step at a time. The time for larger strategic changes will come with time and may result in reorganization of the business. You will weave in all the elements of a lean environment such as value stream maps, kaizens, standard work and 5S in the ongoing change plans. The overall goal is to create a culture that self-actualizes itself to the best in the business sector.
organization. Several small changes will involve more people and therefore can be more effective to promoting a culture change.

May 27, 2016

Micro Management Can Kill an Organization’s Creativity

Managing your team is key to success. That does mean micro-managing them, but merely is the re-enforcement of the common vision, cross checking to the strategic plan, and removing the roadblocks that may be interfering with their success. Many of today’s leaders believe they must micro manage their team. That quickly tells the team that you do not trust them or their skill sets. It eventually removes the ownership of accomplishing the plan from the team to the leader. Team members begin to become less driven to accomplish goals and feel that any accomplishments will be minimized or second-guessed by the manager. So why do managers micro manage? If you read textbooks, they will tell you that it is their own insecurities or their belief that they are more skilled or talented then their team. If that is true, these leaders should not be in a leadership role. There may be people who have unique talents or skills in distinct areas but few people are so ingenious that their knowledge surpasses a team of skilled people.
A true leader is a visionary that polls their team for unique strategic plans. A leader is not more intelligent or driven than his/her subordinates but respects the team and seeks out ideas that will make the team successful. Micro managing is a disease to the engaged workforce and sustainability of the mission. Be a leader and embrace the team’s ideas. It is acceptable to hold the team accountable to deadlines but be willing to remove roadblocks and celebrate success. Recognize the team’s abilities and enhance them with vision and support.