The Internet of Things – IoT (Wikipedia) is the network of physical objects or “things” embedded with electronics, software, sensors, and network connectivity, which enables these objects to collect and exchange data.
The IoT has created a lot of conversations, some stating it’s all hype, some questioning it’s benefits more of something for the future and obviously the ones in support.
Now let’s not pretend here, the IoT is already here, we have smart houses, apps for lights, heating, music, etc. Recently, my neighbours installed a security system which allowed them to view, check, and switch their alarm on and off accessed from internet, this also alerted him to security issues around the property (the most important aspect). So we can’t say it’s not here already.
Now put this into the manufacturing environment.
Some renowned manufacturers have already started investing in hardware, software, and networking systems. Build the IoT infrastructure now to capitalise on its benefits.
I read in an article recently that GE anticipates $19 trillion in profits and cost savings projected over the next decade.
One major area I can see the benefit is Energy Efficiency. To be able to track all facilities, machines energy consumption on a granular level, this visibility will give feedback on a machines abnormal to normal status, something that we can action, countermeasure, control. It will highlight our waste, our areas for improvement, and better understanding of our costs and how to control them. And as stated this has to be a major benefit for manufacturing, something I certainly wanted as an Exec.
The ability to benchmark similar machines/resources, predict maintenance issues with surges in unusual energy consumption, highlighting the out of hours energy waste and being able to control and manage this. All of these will have a direct impact on the bottom line and this is just scratching the service.
The connectivity within production processes is another example, let’s say a machine is not running at optimal performance, this machine would send an alarm highlighting it’s situation to the production team, it could then slow itself down (as not to self-destruct) communicate with its upstream and downstream processes and slow them down limiting the amount of lost production and or downtime and controlling the standard in process stock.
Bosch’s Stefan Ferber stated “The Internet of Things allows for a new way of organising industry production: by connecting machines, warehousing systems and goods, we can create smart production systems that basically control each other without requiring any manual intervention.”
I will always remember the saying “ the Data will set you free” by allowing you to make “Informed Decisions”, can’t get much better than real time data, and that’s the possibility with IoT.
The Internet of Things global economic impact is massive. Approx. 25% of Global Manufacturers are already using IoT technology, this is expected to grow to 80% by 2025. In reading different articles/surveys most cannot put a definitive figure on the potential impact but the range is between $1.9 to $14.4 trillion dollars on the global economy.
Digital Manufacturing Stats from ASQ:
The American Society for Quality (ASQ) surveyed manufacturing companies that have digitised their processes and found astounding results:
82% increased efficiency
49% experienced fewer product defects
45% increased customer satisfaction
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Raising Performance is always a challenge (many a sleepless night) but it’s not just about getting it right in your manufacturing processes, it’s about looking at your business as a whole.
Recently, we were asked to support a £40m turnover company with an objective to reduce costs.
Now, although Reducing Costs (and in particular eliminating waste) is an excellent focus, you can sometime lose sight of what other advantages/opportunities there may be, new market opportunities, sales optimisation, finance, etc.
During our detailed business diagnostic, it became apparent that there were some fantastic opportunities to be realised with particular projects on Increasing Growth and Efficiency Savings.
With TCMUK’s Business Practitioners coaching and mentoring our customers internal team, a total of £700K+ efficiency savings, £1M in cash flow improvement and a 17% growth opportunity have been realised so far within the business, with further projects being highlighted for implementation over the next 2/3 years.
So remember, step back and look at the whole business not just the usual suspects (this goes for any size organisation) and you’ll be confident (and hopefully sleeping) knowing you are focused on the right things.
And don’t forget, if getting results like this is on your agenda and you’re looking for some sector expertise, call on 0330 311 2820
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I’ve recently read articles on Lean Manufacturing and in particular how certain businesses have been re-thinking the implementation of Lean.
Now for a bit of background on the articles. All of the business Leaders that started the implementation had been replaced and within 6 months of them being replaced the new Leader had decided to drop the programme. Now most of the stakeholder’s state that their objective is to address the challenges to delivering high-value to the customer, mmmmmm I wonder? By agreeing to drop a programme of business improvement?
Yes, lean takes time, yes lean utilises the front-line workers, yes you have to manage it and believe in it, but Lean is a long term strategy, a set of principles on how you do business, your business DNA. I wonder sometimes with the drive for instant results in a short space of time, particularly from stakeholders, the impatience for money, dividends, investors ultimately see the Leader that introduced the programme removed. This leads me to believe that stakeholders/leaders are either, ignorant, arrogant, none the wiser or have their own interest at heart, on what long term strategy and Implementation actually and physically means. I have been told about the removal of 11 Operations Managers over a 18 month period due to perceived lack of results, you cannot be that wrong in your recruitment process (or perhaps you can but that’s a separate discussion), so leads me to believe it’s the level above that’s the issue.
Now don’t get me wrong, if your haemorrhaging money within operations due to scrap or process variation don’t go and implement a 5S programme. Instead stop the haemorrhaging by attacking the root causes for variation and scrap, get controllable and predictable outputs. 5S may be part of the implementation but it’s not the saviour.
I worked in a number of businesses in my career and still see the same issues regarding short term results oriented thinking that has cost millions (and yes I mean millions in some cases). When I actually know that had the Lean Initiative programme, Operational Excellence, etc. been executed and maintained when it started, those losses wouldn’t have appeared and would have been quite the opposite.
Cost cutting is often a major reason for ditching the latest programme, and Leaders think that through the force of their personality or financial acumen that they are going to be able to fix the business without the aid of every employee in the business, how foolish are they??????
Any Improvement Programme is not going to be easy, but the benefits are massive for everyone, it takes time but ‘time’ is not a reason not to try.
What did make me smile was one of the businesses new Leaders justified the termination of the programme due to that fact that the frontline workers were involved, but in involving them had potentially reduced turnover times by 6.5 mins which equated into £410000/year of increased revenue.
Lean Manufacturing, business Improvement, whatever you call it, is not a short term strategy, but that’s not a reason not to pursue it.
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I’ve never been one to shout about Lean, Six Sigma or Theory of Constraints, to individuals to solve a solution. I personally have though, applied the tools and techniques to resolve a situation or gain an opportunity I have faced. Granted, it’s not just about the application of tools and techniques, it’s equally important to focus on People, Culture and Managing Change within today’s organisations and society. Every single person has touched or been a part of a Lean process, within our everyday life from grocery shopping to our work we will have been in contact with lean in motion.
The interesting thing I have noticed recently are the articles beginning to appear regarding “is Lean at a crossroads?” and “How Lean is perceived today” particularly in the UK (but perhaps globally). An article by Morpheus Group stated “Businesses are taking a much more pragmatic approach, using a blend of tools….with very few businesses labeling their Corporate Programmes as Lean”.
It does seem that Lean and other Japanese terms associated with it are perceived a risk to alienating the workforce. I wonder why? Are we that uncomfortable with something that is not invented by us?? Are we hiding behind the terms as an excuse not to change??? (There is no doubting it is hard to implement and sustain, but that should never be an excuse). When I personally think about these questions it’s never been about the wording (don’t get me wrong I do cringe with some of them) but it’s about the application, execution/implementation that is key and the right behaviours that drive it so that we can benefit from it.
Businesses are placing a lot of importance on Strategic Cost Saving and Quality. This is absolutely fundamental in “Change” for any business. Strategy and Performance Management, Policy Deployment, Hoshin Kanri, whatever you choose to call it, is the back bone of your business, it is how you do business.
I believe Business Improvement is more important today than it ever has been with the globalisation of markets. What is it that gives us the competitive edge? In particular UK Productivity remains below pre-recession levels. I have been in discussion groups where an estimated 40% of productivity is lost through non value added activities, an estimated £3 Billion cost. Something Lean, Six Sigma, TOC can certainly impact.
This debate will carry on and involves so much from skills, impact on society, etc., etc.
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If your managing time in all sectors of the business, from Sales, Product Development and Production it will result in shorter planning and development cycles, as well as less process time in manufacturing.
Whether you’re a manufacturer making computer components, tin cans, widgets or an individual working in a purchasing department producing orders, reports, or budgets you are still producing an output, an output that someone wants.
We all have our processes (inputs) and transform them into something someone wants (outputs).
Time is the key element to control within our processes, for this we use standard work.
The establishment of time based standardised processes is the greatest key to creating consistent performance. Only when the process is stable you can begin the creative process of improvement.
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**No images or Business Name as Customer NDA in place**
Opportunity
This Private Equity owned business was under performing against budget. Particular attention was required within the operational areas with Productivity and On Time Delivery drifting.
The Managing Director required a system to: communicate the strategy, allocate resources, focus and align actions, and control business drift. He wanted to ensure that all key improvement activities had ownership, responsibility, accountability and the relevant training and practitioner support required to increase overall company performance.
Improvement
Working with the Managing Director & Executive Team the decision of implementing Strategy Deployment and A3 Problem Solving was agreed along with hands-on project execution support.
Training was given to all Management and Leaders in what Policy Deployment and A3 Problem Solving is, what benefits and how the process should be structured to enable execution of the business objectives. Key fundamentals were as follows:
Identify the few, long term breakthrough objectives that are critical to long term success of the company.
Link these objectives with specific action plans throughout the organisation.
Focus and align the company’s internal organisations to achieve these long-term objectives.
Turn the strategic plan into a year – over – year action plan.
Coaches and Mentors others
Workshops were held to ascertain the critical improvement activities to be focused on within the business. Training and Coaching was given to the owners of each A3 Plan on how to manage and communicate through the A3 process. Guidance and training to understand background, current state, problem definition, analysis, actions and follow up.
Management Control Rooms were introduced with regular performance reviews held with all owners and stakeholders present. Ongoing coaching and mentoring in Management Behaviour for the process along with business improvement training and our Lean Coaching Programme to ensure execution and sustainability. Operational Excellence and Process Optimisation workshops/projects were completed covering Sales, Purchasing & Logistics, Operations and Planning.
The company significantly impacted it’s financial position over a 9 month period,
Increasing Sales by 20%
Delivery by 33%
Efficiency by 28%.
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In the world of lean manufacturing, ‘The 7 Wastes’ are infamous for their stealthy operations, silently chipping away at profits and productivity. These wastes fly under the radar, often going unnoticed by even the most astute professionals. Yet, if left unchecked, they can cripple an organisation’s ability to remain competitive and responsive to customer demands.
The Infamous Seven: TIMWOOD
Meet the hidden culprits named TIMWOOD, an acronym that represents the seven wastes in manufacturing:
Transport (Unnecessary Movement of Materials)
The unnecessary movement of materials from one place to another is often the result of poor shop layout or a disjointed process flow. This waste can lead to an increase in handling which may cause damage or loss of materials, delays, and added labour costs. Eliminating this waste requires a streamlined approach to layout design and process flow optimisation.
Inventory (Excess Products and Materials)
Excess inventory is a common issue where production outpaces demand, leading to tied-up capital, storage costs, potential obsolescence, and increased risk of damage or loss. Inventory levels should be scrutinised, and techniques such as Just-in-Time (JIT) production and demand-driven planning should be considered for improvement.
Motion (Unnecessary Movement by People)
Similar to Transport, Motion refers to any movement by employees that does not add value to the product. This can range from reaching for tools to walking between workstations. Reducing unnecessary motion is integral to improving ergonomic conditions and efficiency. This reduction can be achieved by redesigning workspaces to minimise reach and travel distance and by standardising work procedures.
Waiting (Idle Time)
When employees or machines are idly waiting for the next step in production, this represents a significant waste of time and resources. This can be due to poor workflow, machine breakdowns, or bottlenecks. Tackling this waste involves a thorough analysis of processes to synchronise work steps and to ensure a continuous flow.
Overproduction (Producing More Than Needed)
Manufacturing items before they are actually required or in quantities exceeding customer demand results in overproduction – the root of many other wastes. This can lead to excessive inventory and increased holding costs. To nip overproduction in the bud, implement pull systems based on real customer demand.
Over-Processing (More Work Than Required)
Over-processing is seen when more work is done on a product than what is valued by the customer. This waste occurs due to unclear customer specifications or internal miscommunication. Reducing over-processing demands a clear understanding of what the customer values and aligning the production process to those standards.
Defects (Production that Requires Rework)
Defects and the need for rework can be the most apparent and costly form of waste. They lead to wasted materials, labour, and time, not to mention the potential to harm a business’s reputation. A culture focused on quality—like adopting Six Sigma or Total Quality Management (TQM)—can significantly curtail the occurrence of defects.
Identification and Elimination Strategy
Recognising ‘The 7 Wastes’ is the first step to effective lean management. It’s essential to develop a keen eye for these wastes and instil this perspective across all levels of the organisation. This is not a “once in a blue moon” activity but a regular practice that should be embedded into the daily routine. Regular audits, employee training, and a culture that promotes continuous improvement are key factors for success.
To embed this practice, create a system of visible metrics and feedback loops. This promotes responsibility and awareness amongst teams. Engage employees in problem-solving and encourage them to take ownership of their workspaces, suggest changes, and implement improvements.
Continuous Improvement: The Lean Way
To enter into a sustainable cycle of continuous improvement, adopt the PDCA (Plan-Do-Check-Act) methodology. Regularly plan improvements, do them in controlled conditions, check the outcomes, and act to standardise and stabilise the improvements.
Key Takeaways
Employing strategies to eliminate the wastes identified by TIMWOOD ensures a company’s ability to thrive in today’s competitive marketplace. By fostering a culture of continuous improvement, providing employee education, and implementing systems that promote efficiency, companies can not only identify waste but turn it into opportunity – for growth, for innovation, and for delivering value to customers that rivals cannot match.
If you need help applying these principles and taking practical steps towards eliminating waste, our team at TCMUK Limited is equipped to guide you through the process. The impact of addressing ‘The 7 Wastes’ can be profound. Call us at 0330 311 2820 or email info@tcmuklimited.co.uk to unlock the full potential of lean in your operation.
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I was chatting with a few contacts recently, and the topic of A3 Problem Solving came up. It got me thinking, and I figured it was worth doing a quick overview of what it is and, more importantly, why it’s so surprisingly effective.
We’ve all been there, haven’t we? Staring at a 40-page report that’s landed in our inbox, complete with dense paragraphs, endless charts, and a conclusion that, if we’re honest, we’ll probably just skip to. Or maybe we’re the ones writing it, spending days crafting the perfect document, only to suspect it will be skimmed at best and ignored at worst. There’s a kind of corporate theatre to it all. We create these huge, comprehensive documents to prove we’ve done the work, but do they actually help anyone think better or make better decisions? Most of the time, I’d argue they don’t. They bury the essential story under a mountain of information.
This is where a beautifully counter intuitive idea comes into play. The idea that you can achieve more clarity, better thinking, and stronger alignment with less. Specifically, with a single sheet of A3 paper.
Problem solving, at its heart, is a thinking-intensive activity. But the act of writing things down, of structuring our thoughts, can massively amplify the quality of that thinking. It forces us to move from a jumble of ideas in our heads to a logical, coherent narrative. The A3 process is a framework designed to do exactly that. It guides us to document key information and decisions at each step of a problem-solving journey. This document then becomes a living thing, something that can be shared with others to get their input, to challenge our assumptions, and to build a shared understanding before any final decisions are made.
It sounds simple, and in many ways it is. But its power lies in a discipline that most of our modern reporting has lost.
So, Why A3? A Quick History Lesson
Let’s get the most obvious question out of the way first. Why the name A3? It’s almost comically practical. The methodology was pioneered at Toyota, a company famous for its relentless focus on efficiency and continuous improvement. Back in the day, much of their communication across different sites, and even different countries, was done by fax. And A3, which is roughly 29 by 42 centimetres, just happened to be the largest size of paper that could reliably fit through a fax machine.
It’s an amazing little detail, I think. A world changing management philosophy constrained and shaped by the technology of the time. It’s a perfect reminder that innovation doesn’t always come from some grand, abstract vision. Sometimes it’s born from very real, very mundane limitations. The size constraint wasn’t an afterthought; it was a foundational element that forced a particular kind of discipline. You couldn’t just keep adding pages. You had to be concise. You had to make every word and every chart count.
This little piece of history is crucial because it gets to the very soul of the A3 report. The key fundamental is not the rigid format, the specific boxes you have to fill in, or the finesse with which you create fancy drawings and charts. To be honest, a beautifully designed A3 that reflects shallow thinking is completely useless. The real point, the thing that makes it all work, is the communication process it enables.
The A3 is the physical manifestation of a problem solving journey. It’s a tool that underpins a deeper process of critical thinking and collaborative decision making. It allows the most critical information about a problem, from its background to the proposed solution, to be distilled onto a single page. This can then be shared across the business, allowing others to quickly evaluate the thought process behind it. It becomes a formal means for requesting support and advice, which in turn aligns everyone in the organisation on how the problem will be tackled and moved forward. It transforms problem solving from a solo activity into a team sport.
Anatomy of an A3 Report
If you look at a typical A3 template, you’ll see it’s laid out to tell a story, flowing logically from left to right and top to bottom. While the exact layout isn’t set in stone, as I mentioned, the format is not the main point, most successful A3s follow a structure that mirrors the Plan Do Check Act, or PDCA, cycle. It guides you through a systematic process, ensuring no critical steps are skipped.
Let’s break down the typical sections.
Title or Theme: This is the headline. It should concisely define the problem you’re trying to solve. Something like, “Reducing Customer Wait Times in the Support Queue” or “Improving the Accuracy of Monthly Financial Forecasts.” It needs to be clear and specific, framing the entire document.
Background / Current Condition: This is where you set the scene. Why is this problem important? Who does it affect? What is the business impact? This section isn’t about opinions; it’s about facts. You need to go and see the process for yourself, what lean practitioners call genchi genbutsu. You should include data, charts, or simple diagrams to show the current state. What does the process look like right now? What is the performance? This section grounds the problem in reality.
Goal / Target Condition: If the last section was about where we are, this is about where we want to be. What does success look like? The key here is to be incredibly specific and measurable. “Make things better” is not a goal. “Reduce average customer wait time from 4 minutes to 90 seconds by the end of Q3” is a goal. It should be a clear, unambiguous statement that leaves no room for interpretation. This target becomes the benchmark against which you’ll measure your success.
Root Cause Analysis: To me, this is the absolute heart of the A3. It’s where the real thinking happens. It’s also the step that is most often rushed or skipped entirely in traditional problem solving. We see a problem, we jump to a solution. The A3 process forces you to slow down and ask one simple, powerful question, over and over again: Why? This is the famous “5 Whys” technique. You state the problem and ask why it’s happening. Then you take that answer and ask why that is happening. You continue drilling down until you move past the symptoms and uncover the true root cause. Often, the cause you end up with is completely different from what you initially suspected. This section might include a fishbone diagram or a simple bulleted list, but its purpose is to show a clear, logical chain of reasoning from the problem to its source.
Countermeasures / Proposed Actions: Only after a thorough root cause analysis can you begin to think about solutions. Notice the word “countermeasures,” not “solutions.” It’s a subtle but important distinction. A countermeasure is a specific action designed to address a specific root cause. This section should directly link back to your analysis. If a root cause was “Inadequate training on the new software,” a countermeasure would be “Develop and deliver a mandatory 2 hour training module for all team members.” You’re not just throwing ideas at the wall; you’re proposing targeted interventions.
Implementation Plan: This is where the plan becomes real. An idea without a plan is just a wish. For each countermeasure, you need to define who is responsible, what specific tasks need to be completed, and when they need to be done by. It’s a simple table: What, Who, When. This creates accountability and turns a good idea into a concrete project.
Follow Up / Verification: How will we know if our countermeasures actually worked? This section closes the loop. It defines the metrics you will track, which should be directly related to the goal you set at the beginning. It also specifies when and how you will check the results. Are you going to review the data weekly? Monthly? This step ensures that the A3 isn’t just a one time exercise but the start of a continuous improvement cycle.
Results and Learning: Finally, once the plan has been implemented and enough time has passed, you document what actually happened. Did you hit your target? If so, great. What did you learn that you can apply elsewhere? If not, why not? This is just as valuable. An A3 that shows a failed experiment is not a failure; it’s a source of incredible learning. This final section captures that knowledge for the rest of the organisation.
The Real Magic: A Tool for Thinking and Talking
So, that’s the structure. But if you just download a template and fill in the boxes, you’re missing the point entirely. The document is just an artefact; the real value is in the thought process and the conversations it creates.
First, it’s a tool for clarifying your own thinking. The constraint of the single page is a powerful focusing agent. You can’t waffle. You can’t hide behind jargon or bury weak arguments in long paragraphs. You have to be brutally economical with your words. The process of trying to fit a complex problem onto one sheet forces you to simplify, to prioritise, and to make sure your logic is sound. You can literally see the connections between the problem, its root cause, and the proposed fix. It makes your thinking visible, not just to others, but to yourself.
Second, and perhaps more importantly, the A3 is a catalyst for communication and collaboration. In a typical corporate setting, a proposal or report is often worked on in isolation and then presented in a big meeting, a “big reveal” moment. This often puts people on the defensive. They poke holes in it, ask questions the presenter isn’t prepared for, and the whole thing can descend into conflict or get bogged down in debate.
The A3 process flips this on its head. The A3 is meant to be a draft, a conversation starter. The idea is to take your messy, pencil drawn A3 and walk it around to the key stakeholders. This process is sometimes called nemawashi in Japanese, which translates literally to “turning the roots.” It’s about carefully building consensus from the ground up. You show it to your manager, to the people who work in the process, to colleagues in other departments. You don’t present it; you ask for their help. “Here’s what I’m thinking, what am I missing?” “Does this data look right to you?” “What are your thoughts on these countermeasures?”
This approach does a few wonderful things. It enriches the A3 with diverse perspectives, making the final outcome much stronger. It builds buy in from the very beginning, because people feel they have been part of the solution finding process. And it fosters a culture of coaching. A good manager doesn’t just approve or reject an A3. They ask probing questions. “Why did you stop your root cause analysis there?” “How confident are you that this countermeasure will achieve the full target?” They coach the author to think more deeply, turning every problem into a development opportunity.
How to Start Your First A3
If any of this sounds interesting, my advice is simple: just try it. Pick a small, nagging problem that you’re familiar with. It doesn’t have to be a multi million pound production issue. It could be something as simple as “Team meetings consistently run over time” or “The process for submitting expense reports is confusing.”
And please, for your first few attempts, follow the original author’s advice and use a pencil and a physical piece of paper. I know it sounds old fashioned, but there’s a reason for it. A PowerPoint or a fancy software template can create a false sense of finality. It looks polished, so we become reluctant to change it. A pencil and paper, on the other hand, feels temporary and iterative. It gives you permission to be messy, to erase things, to scribble in the margins, and to focus purely on the quality of your thinking, not on your graphic design skills.
Walk through the sections one by one. Go and observe the current condition. Talk to the people involved. Spend a good amount of time on the root cause analysis. Don’t just accept the first answer that comes to mind. Keep asking why. Then, once you have a rough draft, go and talk to someone about it. See what they think. Your first one won’t be perfect, and that’s completely fine. The goal is to practice the thinking discipline, not to create a masterpiece.
Over time, you’ll find that the structure becomes second nature. It becomes an internal mental model for how you approach any problem, whether you’re formally writing an A3 or not.
A Way of Thinking for Everyone
While the A3 report was born on the factory floors of Toyota, its application is truly universal. It’s a mistake to see it as just a manufacturing tool. At its core, A3 thinking is simply a structured, collaborative, data driven approach to problem solving. And what part of a business couldn’t benefit from that?
Think about it.
A marketing team could use it to analyse why a particular campaign underperformed, digging into root causes related to audience targeting, messaging, or channel selection, rather than just shrugging and moving on to the next thing.
An HR department could use it to tackle a problem like high employee turnover in a specific team. Instead of jumping to solutions like a pay rise, they could use the A3 process to uncover deeper issues related to management style, workload, or career development opportunities.
An IT team could use it to finally solve a recurring network outage, systematically investigating the root cause instead of just rebooting the server every time it happens.
Even at a strategic level, a simplified A3 format can be used to propose a new business initiative, outlining the current market condition, the proposed goal, the analysis behind the proposal, and a high-level implementation plan, all on one page for senior leaders to review.
The principles are always the same: Go see for yourself. Grasp the current situation. Analyse down to the root cause. Build consensus around effective countermeasures. And follow through to ensure they work.
In the end, the A3 process is a powerful antidote to the complexity and information overload that plagues so many of our organisations. It’s a call to return to a more disciplined, more thoughtful, and more human way of solving problems. It reminds us that clarity doesn’t come from adding more information, but from stripping away everything that isn’t essential.
It proves that sometimes, the most powerful and persuasive story you can tell is the one that fits on a single sheet of paper.
It’s been an interesting month, great meetings, new contacts and one of the most interesting presentations I‘ve given regarding Operational Excellence and Problem Solving.
The presentation was given to the Manufacturing and Construction sectors as part of a Seminar/Workshop.
The comments at the end we’re ones I have heard over and over again, “We’re Different, it won’t work here!”
Is “we’re different” an excuse not try to improve?
This got me thinking in one of my reflective moments, what is it that naturally creates this push back? Do we think that Business Excellence, Operational Excellence,Lean or Six Sigma is a technical tool and technique, only applied to manufacturing, high volume processes, etc? Is it we naturally assume that it’s for the automotive industry?
There are a number of answers you can come up with that can be assigned to this emotion and push back.
So we have to ask ourselves
Do business improvement principles (as that is all they are) apply to pretty much every process? Yes, I’d say so. Does that mean its easy to put in place? Absolutely not. But that, along with being different, should be no reason to not try.
Which leads me on from last month’s article REFLECTION! and into OPERATIONAL EXCELLENCE TRANSFORMATION
We must first seek to understand what is it we are trying to solve, what problem? This could be as an organisation, function, sub-process.
Then we must ask,
What process improvement needs to be done? What do I need to design, re-design, improve to solve our problem and achieve our objective?
Next,
Do I have the capability in house? Do I have the skillset within my team?
We then come to,
What mindset do I need to have? Growth? (One of learning as we do not have the capability in house), Implementation (I have the capability so execute, or get support if you don’t), Experimental (try and test)
Remembering that Leadership behaviour and Programme Management are the key. The governance process you apply.
Final thought – it’s often said that “Operational Excellence doesn’t succeed or fail… it’s just a set of principles. What succeeds or fails is the organisation or the leaders who try.” Success isn’t guaranteed — it requires hard work and creativity to figure out how will work in your setting, because you are different!
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Just reading though an article (again) in the UK Manufacturing Review and felt compelled to quote James Selka (CEO of The Manufacturing Technologies Association).
I have to say James is spot on with his comments.
“We are living through an explosion in the potential of technology, and it provides a most wonderful opportunity to reinvigorate the manufacturing sector in the 21st century.”
“Manufacturing is remarkable because of the multiplier effect that the sector has. It is so complex, and touches so many other sectors, that activity in it acts as a stimulus to the economy as a whole.”
“As technology becomes more central to the process of manufacturing, the cost of labour – the rationale for much of the offshoring that took place – is a smaller and smaller proportion of the cost of manufacturing activity. Labour cost becomes less of a driver…”
“This is not just about what others can do for us, but what we – UK Manufacturing – can do to help ourselves”
Extracts taken from the UK Manufacturing Review 2015 -16 (Stirling Media).
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