Organizational Features of a Lean Plant

I’m reading The Machine That Changed the World : The Story of Lean Production by James P. Womack, Daniel T. Jones, and Daniel Roos. It is an extremely interesting book.

I ran into this small paragraph yesterday that for some reason stuck in my head as something important:

The truly lean plant has two key organizational features: It transfers the maximum number of tasks and responsibilities to those workers actually adding value to the car on the line, and it has in place a system for detecting defects that quickly traces every problem, once discovered, to its ultimate cause.

I’m telling you, the Poppendeick books are great, but there is nothing like going right to the source for an explanation of lean. I’m about 100 pages into the current book and I am absolutely fascinated at how much of todays current corporate structure (multi-level, many people with very specific task sets or responsibilities) is based on things that Ford and Sloan did with their companies.

In IT, this management style is manifested through all the different groups one hears about all the time from people in the field: Development, Infrastructure, Business Analysts, Quality Assurance. Each its own little silo, with its own responsibilities – and never should one group know how to do, or be privy to, the information in one of the other groups. Handoffs occur between the groups via very large documents.

Sometimes it goes further than that. I was talking to a friend once (who worked at another company, BTW) who told me about how their DBA’s were responsible for uptime and performance of the database and had decided that developers were not allowed to use ORDER BY clauses in their SQL because it effected the performance of the database. These developers were actually forced to sort their results within the application, rather than use the capabilities of the database, adding additional complexity to an already complex application. Worse, management seemed to buy into the decision, as I don’t think I would have been hearing about the situation if it was overruled. Ridiculous.

Another quote from the book, same page:

In old fashioned mass production plants, managers jealously guard information about conditions in the plant, thinking this knowledge is the key to their power.

Again, shocking how much of this mentality you read about in corporations not even connected to automobiles. This sounds like just about every company I’ve talked to people about (or worked at) over the years.

I’ve come to the decision over the years that ultimate transparency is the key to breaking down silos. It only breaks down your silo, but hey – thats a start, and at least you are setting an example.

Its definitely very beneficial, I’m finding, to read about things that are completely outside your profession to give you some distance from what is being taught. The lessons flow in easily this way, because you don’t have the predisposition that you “already know how things work”.

I recommend to anyone in IT to pick this book up. Its absolutely fascinating.

Calacanis Interviews Evan Williams, Co Founder of Twitter

I really enjoyed Jason’s interview with Evan Williams (co-founder of Twitter, Odeo, and Blogger) especially Evan’s “lessons learned” about entrepreneurism:

1. Focus
2. Small things can become big.
3. Don’t go too wide.
4. Trust your gut.
5. Don’t do anything you aren’t absolutely passionate about.

The Shoemakers Son Always Goes Barefoot

The other night the ignition switch on the furnace went out in the house. I watched as Jonna spent a ton of time searching for the contact information for the guy who came out the last time we had a problem. It took quite a while to find the information, but finally she found it. When she got a hold of him, he started asking questions about a blinking light on the furnace. We had no idea what he was talking about, but I did remember he gave us information last time he was here – I just couldn’t remember what it was.

Yesterday as I was driving to work, I was reflecting on the activities of the night before. Why did we not have this information available when we needed it? Where could we put it so that if something happened again, we could have it readily available? How can we take these kinds of notes effortlessly and ensure that we know where we put them?

Then a stark realization hit me. We’ve already solved this problem – at work.

In early 2004, at the urging of one of my direct reports, we installed wiki software at the office to solve just this problem. All of our information was scattered around network drives, none of it really searchable. Doug was very into Python at the time so we chose ZWiki, a wiki package that runs on the Zope application server. We used that for about 1 1/2 years until we finally bit the bullet and moved to MediaWiki, where our information repository lives today.

We actually have quite a knowledge base going there now, everything from detailed process information, to configuration information, to even some projects that are being managed on the platform, with detailed information about all of the issues encountered, configuration information, and the like. It has become a one stop shop for all information related to our environment.

And I’ve been the primary champion since it was installed.

This was when, as I was sitting in the car pondering this, that the title of this post came to me. The old adage is true. There are so many problems that we solve in our daily business lives that never get resolved in our personal lives, and vice versa. Its amazing to me that while we’ve done so much at work to centralize the information in our department (while decentralizing the authoring so that if something is found to be wrong it can be corrected) that I never thought to apply this at home to keep all of our information straight here. Instead, Jonna spends countless amounts of time searching through kitchen drawers for information on service providers and I sit trying to remember that one valuable piece of information that the furnace guy absolutely needs so that he can arrive and fix the part, rather than wasting trips to and from our house to first diagnose the problem, then go get the parts to fix it.

So, I’ve spent this morning getting MediaWiki running here at the Labs. Hopefully, I can motivate the family to use it as we have motivated our employees to use it at work to keep all of our important information centralized and updated. Its a simple thing to set up, but can be rather difficult to socialize. Luckily, we only have 5 people here, so the socialization might be a tad bit easier to do.

How many things do you struggle with at home that have been solved for years at work? Maybe you even had a hand in solving them, but the solution never seeped into your life outside of work?

This was a major “AHA” moment for me this week and I’d love to hear about other people who might have similar stories.

Now I’ve Heard It All: Management Lessons from RoadHouse!

One of my favorite “bad” movies that I just cannot switch past when its on is the movie “Road House“. As a matter of fact, we went out and bought the DVD so that when it is on TV, I can pop in the DVD and watch the “unedited” TV version of the movie – thats how addictive the movie is to me for some reason. I just cannot “not” watch it when its on.

So imagine my surprise when the latest episode of Manager Tools used Roadhouse as one of their examples when discussing Handling Peer Conflict When Your Directs Are Involved. The example was around one of their steps in handling conflict, which was “Turn the other cheek”. In the movie, there is a scene in which Patrick Swayze is laying down the rules for working in the bar now that he has been hired as a cooler. Oddly, the scene really does illustrate the point Mark was making quite well:

DALTON:

1. Never underestimate your opponent. Expect the unexpected.
2. Take it outside. Never start anything in the bar unless its absolutely necessary.
and

3. Be nice.

EMPLOYEE:
C’mon

DALTON:
If someone gets in your face and calls you a <bleep>, I want you to be nice.

EMPLOYEE: OK …

DALTON: Ask him to walk, but be nice. If he won’t walk – walk him – but be nice. If you can’t walk him, one of the others will help you – and you’ll both be nice. I want you to remember that its a job. Its nothing personal.

EMPLOYEE 2: Uh, huh. Being called a <bleep> isn’t personal?

DALTON: No. Its two nouns combined to elicit a prescribed response.

EMPLOYEE 2: [laughs] Well what if someone calls my mama a whore?

DALTON: Is she? [pause with employee laughter] I want you to be nice until its time to not be nice.

EMPLOYEE 3: Well, uh, how are we supposed to know when that is?

DALTON: You won’t. I’ll let you know. You are the bouncers, I am the cooler. All you have to do is watch my back – and each others … and take out the trash.

See video below.

I guess it just goes to show you that there are leadership lessons everywhere, you just have to be looking for them. Road House, honestly, would have been the last place I would have looked, but damned if they aren’t there as well.

As an aside, I’ve just started reading a book called Leadership Sopranos Style: How to Become a More Effective Boss. Again, another place I would not necessarily look for leadership lessons. The book is pretty good so far. I’ll probably write something up on it when I finish it.

I like books and lectures that use pop culture to make the concepts more accessible. We need more of this in the world, rather than the dry theory of most leadership related material.

HowsThatJob? : Starbucks rates in bottom 5

Aside

Before people start pegging me as someone who only sees the positive in Starbucks as of late, it is worth mentioning that a new site, Hows That Job?, has Starbucks listed in the Bottom 5 companies. Now, the site only has 45 reviews right now (in total – with only one for Starbucks) – but it is an opposite point of view. This reviewer also qualifies the rating, saying that it was the customers that made it terrible.

Starbucks Green Apron Book

Photo by rbieber

Did you know that you could just walk into your local Starbucks and request a "Green Apron Book", that outlines the principles of Starbucks? I heard about this little booklet from a recent book I had read about the company and went in to my local Starbucks and asked for a copy. I was a tad surprised when the employees were extremely happy to give one to me. There’s something to be said about a company that is not afraid to share their core principles with their customers. There’s much more to say when they do it so enthusiastically.

I was totally impressed with being able to walk into my local Starbucks and get a copy of their “Green Apron book” after reading The Starbucks Experience: 5 Principles for Turning Ordinary Into Extraordinary.

I did find another review of the book and it was really cool to me that the reviewer offered the same observation that I did around the structure of the Starbucks principles:

After reading it that afternoon, what impressed me the most was the absence of rules. In their place were suggestions, goals, and the empowerment to make every customer’s experience a memorable one. It was at that moment that I realized the significance of Starbucks’ philosophy—not only for business, but for life in general.

This really parallels my thoughts on what I had read:

One thing that comes out fairly strong in most of the books I read about Starbucks (and Toyota as of late) is the acknowledgment of senior managements importance in setting the culture, ideals, and principles of the overall business while giving the “people doing the work” the ability to act within the framework of the principles.

Another cool thing I noticed. When you dig down into the detail of the Be Welcoming principle, you find the following:

Get to know your customer by drink or name.

This completely impressed me – because I experienced it. As a matter of fact, it impressed me so much that I wrote about the experience in the post “ Reaching “Norm” Status – The Ultimate in Customer Service” back in March of 2005.

Books: The Starbucks Experience : 5 Principles for Turning Ordinary into Extraordinary

For some reason, if there’s a business book related to Starbucks, I just have to pick it up and usually wind up going through it as quickly as one of my favorite mocha’s.

This week I ran across The Starbucks Experience: 5 Principles for Turning Ordinary Into Extraordinary by Joseph Michelli. This book is the result of an 18 month study of what makes Starbucks work by the author.

Starbucks has been one of those companies that completely fascinates me. From everything written about them, they are run a lot differently than most companies one reads about. Their commitment to their customers, employees, and communities in which they reside is really unparalleled in the business world and I am constantly wondering how they make it work.

This book gives you some insight. In it, Michelli outlines the 5 principles that the Starbucks leadership team instills in its “partners” through tons of training and consistent modeling of behaviors by senior management.

  1. Make It Your Own – Starbucks goes to great lengths to educate their employees on their products. They also allow their employees (or “partners” as their called) to do whatever it takes to ensure a positive experience by the customer of the company. Each employee is encouraged to take action as if the company were his own.
  2. Everything Matters – Starbucks employees are trained to pay attention to the smallest details. Within this principle the author makes a distinction between “above deck” and “below deck” activities. The “below-deck” activities are those which the customer does not see. Great care is taken at Starbucks to pay attention to the “below-deck” activities. Traditional business find it “OK” to cut corners on below-deck activities to cut costs. Starbucks views these activities as just as important as customer facing ones. It is understood at Starbucks that in order to deliver quality, you have to deliver it at all levels of the business. Any compromises can relax “quality awareness” throughout the organization.
  3. Surprise and Delight – Cote actually addressed this principle fairly well in a recent posting where he talks about how companies can “unexpectedly delight him” by doing things he wouldn’t expect but are useful to him, the customer (see the “Making My Life Easier” section). At Starbucks, one of the primary principles the company is built on is cultivating this ability to delight customers and go beyond their expectations. The book gives some really good examples of this type of behavior.
  4. Embrace Resistance – This principle is all about accepting feedback, both positive and negative – and using the negative feedback to feed into the business to find lessons to improve. The company finds all feedback important. A recent example of this is its response to Oxfam America and its efforts to get Starbucks to use its leverage to stand up for the Ethopian Coffee Farmers. Rather than ignore the feedback, Starbucks responded – constructively and calmly, explaining its position on the issue. Accepting and responding to feedback is built into the core principles of the company.
  5. Leave Your Mark – The final Starbucks principle is built around being involved and contributing to the communities in which it resides. Starbucks has a strong commitment to contributing to the community around them. This chapter focuses on the social aspects of the company, including its activities concerning the environment and various social issues.

To me, these seem like some pretty solid principles to build a business on. It almost seems “too ideal to be practically possible”. One thing that comes out fairly strong in most of the books I read about Starbucks (and Toyota as of late) is the acknowledgment of senior managements importance in setting the culture, ideals, and principles of the overall business while giving the “people doing the work” the ability to act within the framework of the principles. It seems that the more I read about these two companies, the more there is in common between them at a high level.

A book that I would be really interested in reading would be a book focused on the IT practices and principles in both companies. It seems to me that it is really easy to push down authority in a company which is distributed across the country, while that same practice in a corporate environment (especially IT, which is traditionally looked at as a “necessary evil” and liability rather than an asset) would be a little harder to foster this type of culture. I would be extremely interested to read an honest, detailed descriptions of how these areas of the company are run within the context of the overarching principles.

But here I go, digressing again. I thought The Starbucks Experience: 5 Principles for Turning Ordinary Into Extraordinary was an excellent book and would recommend it to anyone managing people. It documents an interesting framework for running a business and is full of great examples of each principle to illustrate application of the principle to “real life” in a business.

Lean Principles from the Source

I’ve started reading The Toyota Way: 14 Management Principles From The World’s Greatest Manufacturer by Jeffrey Liker. I’ve figured that as my curiosity peaks on Lean Development and Lean Principles in general, I might as well go to the source.

Chapter One opens with a quote from Fujio Cho, the president of Toyota Motor Corporation from 2002. I read the quote and thought I’d post it up here.

We place the highest value on actual implementation and taking action. There are many things one doesn’t understand and therefore, we ask them why don’t you just go ahead and take action; try to do something? You realize how little you know and you face your own failures and you simply can correct those failures and redo it again and at the second trial you realize another mistake or another thing you didn’t like so you can redo it once again. So by constant improvement, or should I say, the improvement based upon action, one can rise up to the higher level of practice and knowledge.

Toyota is thought of as one of the most process oriented companies around, and yet they still acknowledge that you do not know everything up front and build that into the process. A book that starts out this way has got to be one interesting read!

A Samari in the Senate: Jason Calacanis Talks About Working in a Large Company

A portion of this weeks edition of the Gillmor Gang (MidTail Gang – part IV – ugh!) really hit home for me this week. At around 14:34 in the sub-episode, Jason Calacanis talks about how he feels as an entrepreneur working in a big company. This section lasts through the end of the sub-episode. You have to give this a listen.

I don’t think what Jason is saying is necessarily only a view from an entrepreneurs perspective, but applies to anyone who wants to execute and has built their career on the ability to execute. As a company grows larger and things get more political, it becomes extremely difficult to execute anything, which can become extremely frustrating for anyone who just wants to get things done without having to talk about it for three months.

One quote that Jason threw out bears repeating:

Centralization and consolidation, I think, are two of the worst forces for building great product. Once you centralize stuff and put in controls, it just – it kills the process.

I think its great that Jason can be so honest about the experiences he is having at AOL. You rarely hear someone talk about these things and it was very refreshing to hear something that hit so close to home.

I must have listened to this section about 4 times last night on the way home. This section, in and of itself, was worth the 5 part download yesterday.