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TRANSCRIPT
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Leading a Lean Transformation
“I don’t know who the hell is in charge,
but it’s not me!”
Mike WroblewskiPresident Dantotsu Consulting
Master Sensei and Author
So you are Leading a Lean Transformation….
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Which path are you on?
Control
“I don’t know who the hell is in charge,
but it’s not me!”
“There are only two things you can control in life, your effort and your attitude”
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Mike Wroblewski
Row Bless Ski
Hill-RomBatesville Casket
Company
My Background
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What does it mean
to create a Kaizen
Culture?
“If kaizen is the work of making our
processes better, creating a kaizen
culture is the work of getting better at
kaizen.”
2015 Shingo Award
My Lean Introduction
1985
SMED
Lesson
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“There are four purposes
of improvement: easier,
better, faster and
cheaper. These four
goals appear in the order
of priority”.Shigeo Shingo
Simply…
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Not found in the tools, it’s the culture!
5S
TPM
Kanban
Value Stream Maps
Visual Controls
Kaizen Events
Poke Yoke
SMED
TESSEI - Shinkansen Bullet Train cleaning company (The 7 Minutes Miracle)
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To make the Bullet Train work, be on time, everytime, with 12 minutes between trains, they had 7 minutes to clean the train.
The 7 Minute Miracle
Current State
Not able to achieve target.Morale LowWork considered Dirty, Dangerous and DifficultHigh TurnoverEmployees viewed themselves as “no good” and “low class”
Management ActionResorted to on the spot reprimands to errant employees.
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Enter Mr Teruo Yabe…..Newly named President (From Safety dept)
Job 1 : Improve Morale
Colorful Uniforms, colorful hatsAct as Train AmbassadorsPut on Show: Shinkansen Theater
Never saying “No” to employee ideas!!!!
How did they create the miracle?
“The only thing of
real importance
that leaders do is
to create and
manage culture.”
Prof. Edgar
Schein
MIT
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• Clean each day
• Put things back after use
• Follow standards
5S Workplace Organization
We must expose problems,
assign no blame, look for
causes and find a better way.
The ABCs of Organizational Culture
Adapted from Prof. Edgar Schein
Five Keys Points for Leading a Lean Transformation
1. Establish Challenge (Vision and Why)2. Start with Yourself First (Lead by example)3. Mastery of Fundamentals (7 Wastes & Root
Cause/Problem solving)4. Communication (Ability to explain so people
understand)5. Develop Others (Teach, Mentor, Coach)6. Kaizen Daily (Don’t hesitate to put in effort to achieve
target)7. Celebrate Effort (Ability to share joy of even small
improvements)
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Vision
Start With Why
“We will do as we are told by someone who
outranks us, but we will only follow someone we
believe in.”
Simon SinekAuthor and Speaker on Leadership
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The starting point for
change is not system
change, not change in
others around us, but
change in ourselves” Michael Fullan, 1988
Think Lean
before
Doing Lean
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What does your typical day look like?
Typical Daily Activities• Meetings
• Reports
• Presentations
• Phone Calls
• Planning
• Firefighting
• Gemba walks
• Audits and spot
checks
• Visual reviews
• Problem solving
• Kaizen
• Training
• Staff Development
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Gemba Gembutsu
Go the the actual place to see for yourself the things to get
the facts (to gain understanding).
Get Your Boots On!
How much time should a leader
spend in gemba?
80%
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Are you working in the system oron the system?
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You will make Mistakes!
Own up to your mistakes and learn from them
Communication
Daily Meetings (Tiered 3 Layers)
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How do you feel today?
Whatsapp!
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Develop Others
Not ThisThis
Teaching, Training, Mentoring, Coaching
Mr Isao Yoshino
Bad News first!
Never be afraid of failure, failure is the source of so much learning
Spirit of the Challenge
Assign task, not the “how”
People grow by looking at the backs of their bosses
Former Toyota Section ManagerTPS Trainer for NUMMI
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Getting Buy In
Trust
Talk
Try
Team
Sharing the knowledge: Japan Study Trip
First Day in Japan with Daniel
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BE PATIENT
It is a slow process,
remember it a mindset change.
“Excellence is achieved by the mastery of the fundamentals”
Vince Lombardi
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Problem Solving
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“It’s not about perfect.
It’s about effort. And
when you implement
that effort into your life
every single day,
that’s where
transformation
happens. That’s how
change occurs.
Jillian MichaelsAmerica’s Toughest
Personal Trainer
Celebrate Effort!
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“Be decisive. Right or wrong, make a decision. The road of life is paved
with flat squirrels who couldn’t make a decision.”
Quitting is Addictive
Gets easier and easier the more you do it
“Never, Never, Never
give up”
Winston Churchill
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Thank you!
Mike WroblewskiPresident
Dantotsu Consulting+1 715-891-7391
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