Video

When the toilets are that good, you KNOW what the product is going to be like. How you do the small things, impacts how you do the big things.

Incredible !

00:39 I believe the addition of even the smallest icons next to QR codes would be much more convenient than just small/long text

You guys mentioned a bunch of whatsapp communities for lean, how would we go about getting access to these communities?

You just made my executive disfunction come back online with a little hope for my life....i don't even know how this ended up in my feed but it's inspired some ideas and applications for my life. ❤

dunknoe my g

Job Instructions resp. Job Breakdowns (from Training Within Industry) can help to find the right level of detail. Initial question in every procedure is WHAT are the important steps (creating value for the customer by a modification done right the first time), HOW to do it (what are the key points to follow in each step, there might be several ones), and equally important (but often forgotten to think about and communicate) WHY do we do it that way, ie. why do we follow that standard?

Thanks!

Crowd sourced improvement: When you stopped production to fix the camera, the problem wasn't solved forever. Matt needs a marker so he knows when he is in camera. To prevent interrupting the flow of the conversation, the producer could give a signal so Matt can correct his positioning.

Why would you create a “standard” and then not follow it? Train to the standard and enforce it. If there is a better way capture it and train to that. Rogue workers cost money.

Do you have to follow the standard every time? Answer in the video → No. That's unquestionably wrong. Better ways of stating it: Do you have to ADHERE to the standard every time? Yes. Do you have to read the standard instructions or watch the standard video every time? No.

I'm sure this will get better, but audio was a little in and out which is really obvious on my Bose headphones. Years ago I did a podcast, the guy running it insisted we wear headphones, I asked why, basically it's because you can hear yourself and then you can catch when you move away or turn your head etc. This issue is mostly noticable where Matt is nodding and talking. Not noticing it on Ryan's side right now. Also don't forget to make use of the link to website feature, at the moment it's just direct back to your channel from bio - where you already are 😅

I am glad you were direct about uncooperative worker. There are times where a leader needs to fire people. If you don't the company will fail.

People and their developed mindsets are at the core of it all! So many businesses - manufacturing and non - do NOT invest properly here, at all. Mostly unstructured or simply lip service. Gold Standard Psychometrics is the missing critical ingredient.

These meetings don't sound very lean. They seem very full, long and choppy. Do you have a video of one of your actual meetings?

We need this in America 😭😭

If anyone is interested in having a true "plug and play /off the shelf" version of this system, please comment here. We reckon we could develop a product like this for around $250 plus small license free. It would be good to see if there is REALLY an appetite for this. I'd love it if there was! 🙂

Awesome Ryan and Stephan. Truly a benchmark for other organizations to compare to. Love all the Firbees and Smiles 😀

Thank you Ryan (and Stephan). I love the sub-4 minute videos because we can easily show them at our morning meetings :)!

Love the idea of capturing all the problems for the morning meeting.

Just started implementing Lean and specifically daily improvements on a machine we use. The machine went from being a nightmare to use and only in 2 months you can now use the machine in your sleep because its so easy and user friendly. We also never had to stop the machine for more than an hour or so every morning to implement improvements so production did not drop. This is amazing, Lean for the win!

So cool. We started using andon’s last year for the following: 1) Kanban card drop boxes 2) Paint Inspection 3) Trigger release of new work. We have flashing lights with tones but added a timer so the tone shuts off after 5 minutes and doesn’t turn back on for 15 minutes unless someone addresses the issue.

What kind of system is this?

Can you share what software and hardware system this company is using for their Andon lights and email alerts

what an amazing system? everyone wins - operator / teamleader / management. QUALITY!

SoP's should be essential for every business. Great podcast

I came to standard work through problem solving. When something was “wrong” asking the question “what should it be” usually. Gets an interesting response. And was almost never documented. Especially painful when working with 4 shifts and no real overlap….

Great questions of Ryan

You guys need to look into system hub and the book systemology .

Great video, Ryan. I have a request/suggestion: It would be incredibly valuable (especially for someone like me just beginning my lean journey) if you made videos going into intricate detail on how you actually/literally execute these concepts. You do this a bit in other videos but you could go into further detail showing real SOP’s being written, what software you use, the chain of communication between employees from new idea, how to update an SOP, publishing it for all employees, how employees are notified of the change. Even if you did one video of one concept in intricate detail I think it would open people’s minds more on how lean works, how you think, how we need to think to get to your level. It might be a very long video but I don’t doubt that all of your subscribers would watch every second of it! Thanks!

Hi Ryan. Love your channel. I watch all your videos. Quick question (I've been trying to figure this out for years): When documenting a new standard work process, do you document the new process immediately the first time you do it? Or do you play around with the process a few times first, tweak it, improve it as much as you possibly can for the moment... then after a few days (once you're satisfied) document it as standard work?

Would love info on leader standard work; our leaders keep trying to use SOPs as a “rules for thee but not for me” manipulation tool, will hold others to them and change them willy nilly to pass the buck but will not use them personally or put enough thought and effort in to set others up to succeed with them. We tried to get them in the habit and seeing the benefit by creating a written standard problem solving process that lays out the PDCA cycle, but they find any excuse to skip it and jump straight back to following their gut and perpetuating their preconceived notions instead of observing and analyzing processes and thinking solutions through. It’s killing our whole lean effort, improvement projects keep dead ending, leaders undo progress inadvertently by rolling out half-solutions and refusing to review and follow updated processes, everyone is demoralized by their behavior as well.

The biggest challenge I’ve run into is taking a design that was not optimized for manufacturing and getting engineering to play nice and change the design. The complexity of customer and governmental approvals for design changes is maddening. Standard work and continuous improvement is great, but make sure you are working with the optimal design.

What is the balance for instructions (SOP) between to simple and over complicating the process. (what can you assume or not)

First time in automotive I see 😂😂😂

Fantastic discussion as always 👍👍. "Documenting highlights the waste" is gold.

“Continuous improvement of the standard” such clear focus, thanks again Ryan! 😎

Brilliant. How do you approve a process change? How do you handle suggested improvements that you know are a bad idea.

Made my weekend meaningful watching this video!! Innovation alone is not enough but the execution matters! Countries lose their jobs to other places not just bcoz of low cost but due to non-lean thinking...

88 secs... Now I can explain the huge body panel misalignment in Toyota's.

This is absolutely true. Developing people is the heart of lean and the age old adage is correct that says "Give a man a fish, he eats for a day. Teach a man to fish, he eats for a lifetime."

It was a pleasure having you. Looking forward to welcome our next guests!

Haste work makes waste work

If you pumping put a car every 40 to 60 seconds per line, you tend to be busy

This is why working on these cars is so damn easy

Toyota is racist, the only hired india people

Fuck doing this as a job. Just fuck this in general.

I think this is his first time in a production facility

Having a way to get help doesn’t mean help comes when you need it

Everywhere has andon cords. That doesn't mean that anything gets done.