Sunday, November 30, 2008

Goal driven retrospectives

When it comes to retrospectives, I've come to emphasise more on setting goals and working out how to achieve them rather than just discussing and responding to past events.

Fabio describes our recent attempt to do this.

This blog is a "Duty Fulfiller"

Via Glen Alleman,

According to Typealyzer, the writing style on this blog reflects the ISTJ Meyers-Briggs personality type, the Duty Fulfiller.

 
 

Thursday, November 27, 2008

Love is blind, but computers aren't

Was looking at Subtext, and stumbled upon an interesting blog entry by Jonathan Edwards on why he didn't contribute to Beautiful Code:

Telling an inspiring story about a beautiful design feels disingenuous. Yes, we all strive for beautiful code. But that is not what a talented young programmer needs to hear. I wish someone had instead warned me that programming is a desperate losing battle against the unconquerable complexity of code, and the treachery of requirements.

Tuesday, November 25, 2008

Our people just don't have any good ideas

Bob Sutton shares a comment made by Matthew May in response to Bob's post on The Auto Industry Bailout:

Thank you for a thoughtful and insightful post. Everything you describe mirrors my experience with a part of GM in the early 90s. I was doing some consulting with a division of GM and told them the best ideas, in fact no ideas, were getting heard. The managers to a person told me that wasn't their culture. During an offside I had the opportunity to design part of the program. It was an age-old prioritization game called Survival on the Moon: you've crash landed on the moon, 200 clicks from the mother ship, with 25 items you have to rank in the order of their importance in surviving the trek to the ship. You do it individually, then as a group, in order to make the point that "we" is smarter "me". (There is a right order, provided by NASA.) I constructed the table rounds cross-hierarchically, so one table might have a vp and a lowly staffer. Then I played a dirty trick: I gave the lowest ranking person at each table the answers ahead of time, saying that when it came time for the group ranking, their job was to everything in their power to convince the table they had the right ranking, short of revealing that I had given them the answer. Not a single table (about 15 tables of 10) got the right answer. Then I had the ringers stand up. Got to catch all the managers red-faced.


I spent 8 years inside Toyota as a fully retained adviser to the University of Toyota. It is the antithesis of everything you describe.

Sunday, November 23, 2008

Process != system

Process is how things are done.  This is not enough.

A system is more than just how things are done.  It includes how people relate to each other and how they are developed.  It includes the technology and tools we use.  It includes everything within our (bounded) environment because all must be considered when changing for the better.

Don't worry about how valuable it will be, just tell me how much it costs?

When designing a solution, it is critical to understand what value it will bring.

I can respond with a very simple but sub-optimal solution if I know the return won't be that significant OR I can respond with a more sophisticated and more expensive solution if the return is significant enough to justify it.

But should I not always have multiple options anyway?

Well yes, but if I knew what the value was, I might flesh out 3 simple solutions rather than 1 simple, 1 average, 1 complex.

In other words, if you filter information about benefits to people who are designing your solutions, be prepared to get sub-optimal results.

Saturday, November 22, 2008

Japan Lean Study Mission Day 2: Sango

On Tuesday we visited Sango, an exhaust system manufacturer and tier 1 supplier to Toyota. Sango had their 80th anniversary last June.

This visit lasted the whole day and most people in the group thought this was the best part of the whole tour.

Plant Tour
New Japanese phrase learned: Pika Pika => spic and span

1825 days without a work stopping accident.

Stand-up meeting every day at 9:30 before production starts where they go over the previous days defects and improvement ideas. They hold this near a problem board area with defective parts and equipment and analysis of why they occurred. I saw a similar area at Toyota Altona where they also has photo binders of past defects.

Key point for me: "Understand what's in front of you"

There were A3 sheets up with an analysis of different movements in terms of ergonomic quality. The range is 0 to -4 where -4 movements were the worst. Each category had visual examples of what the bad movement is. For example, having to do a full rotation. A goal is then set to remove all the -4 movements from standard work, and then -3 movements, etc. Saw the same thing at Toyota Altona.

[Would it be useful if we could set categories to different types of Checkstyle failures? Would this be useful to systematically but incrementally ratchet up the design quality of legacy code bases?]

Key point for me: Use before and after pictures

Training dojos exist for new employees, as refreshers, and for team leaders.

The purpose of a Standardised Work document:

  1. Teaching tool
  2. Checking and confirming
  3. Tool for kaizen
There is Portuguese everywhere. A lot of Brazilians in Japan.

A rest area was created to improve communication and cohesion amongst team members. This was done with weekend overtime rates.

There was a lot of ambient noise and no visible ear protectors... Aural indicator options were limited. Strong contrast to how sound is used to indicate problems at a Toyota plant.

Presentations
After the plant tour, we migrated to Sango's newly built training centre to have lunch with Sango employees learning English and then listened to a series of presentations from Sango senior managers.

Senior Managing Director Keisaku Inoshita
Mr. Inoshita was previously the president of Guangqi Toyota Engine, Ltd and was also involved when Toyota started in North America. From what I'm told, this is a common occurrence where senior Toyota people will retire earlier and spend the remainder of their career working with suppliers to develop them.

In English and in Chinese, the phrase for one half refers to the result, that something is one half of what it was. In Japanese, one of the characters used contains the ideogram meaning sword. In this case the method of getting one half is emphasised. This demonstrates the difference between results-thinking and process-thinking.

Imagine that we want to buy a robot. The robot also comes with an extra frame which we don't need now but makes it cheaper to install more robots. That extra frame is waste. We may never need to buy more robots.

[Don't write code for extra features until you need it. That code is waste. Those features may never need to be written.]

Pay the most attention to fixed costs.

Pika Pika is important because it makes it easy to detect problems.

We work on machines to change people. Changing people changes the organisation.

They used to have a problem with waste material accumulating underneath the large stamping machine. Couldn't clean it except at stoppage times. The only stoppage times were at lunch. Can't ask the workers to sacrifice their lunch to do the cleaning. Therefore the area was cleaned by managers over a 2 month period.

Train people to see what is normal vs abnormal.

[Clean Code is not just about aesthetics; it's about making it easy to see problems and to train people to see what is normal versus abnormal.]

Removal of unnecessary things is the most basic of the basics of visual management.

"No problem is a big problem". It indicates a lack of capability of finding problems.

Start with simple things, and grow to more complex things. Start on the surface and move deeper and deeper. This is a PDCA spiral from simple to complex.

Start with simple things => Anyone can clean.

Reduce, Reuse, Recycle is a well-known sequence. Before the 3Rs, think about one more R: Refuse. If I don't have the machine or the part, it doesn't break down.

[A feature that isn't written doesn't have defects]

Focus on real value-adding kaizen, not just kaizen for show.

Officer Masahisa Kishi
Had been with Toyota since 1975.

3 stages of human development:
  1. The ability to make things.
  2. The ability to make a system, structure, and device. Finding and solving problems.
  3. The ability to develop people.
Q&A and general discussion

Q: What advice would you give to a company just starting out?
A: Sincerity

Q: What is done for forecasting and planning?
A: 2 times a year there is strategic planning. There is a 3 month plan with a 1 month plan for fixed orders. Kanban is used for fine-tuning.

It's easy to make 400 cars with 400 people; it's hard to make 4000 cars with 4000 people.

There is "valuable cost" and cost that is just waste.

Higher bonus = poorer performance

Dan Ariely on the value of big bonuses:

We found that as long as the task involved only mechanical skill, bonuses worked as would be expected: the higher the pay, the better the performance. But when we included a task that required even rudimentary cognitive skill, the outcome was the same as in the India study: the offer of a higher bonus led to poorer performance.
Via John Hunter.

Friday, November 21, 2008

GM and "No We Can't"

Bob Sutton's Thoughts on Why GM Executives are Clueless.

Thursday, November 20, 2008

Our real production is developing people

Marcel McLeod, managing director of Total Fab, was a fellow member on the Lean Journey Study Mission to Japan.  Here's an article about him in the Townsville Bulletin (click on image for a larger version):


My main thought is that real students of Toyota and Lean speak differently than people who don't quite get it.  Marcel is a good example of a real student.

Tuesday, November 18, 2008

Is design purely subjective?

Design is purely subjective only if design is solely about aesthetics.

Sunday, November 16, 2008

Japan Lean Study Mission Day 1: Aichi Sangyo and Toto Bath Create

Kevin Meyer described his experiences with Gemba Research's Japan Kaikaku Experience so I figure I should do the same for Enna's Lean Journey Study Mission to Japan.  I'm a software person, not a manufacturing person so forgive any strangeness in what I observed and paid attention to.

----
On the Monday we visited two companies, the first being Aichi Sangyo, a welding technology company that has been operating for 71 years.

Some interesting points during the presentation by the Managing Director:

  • small to medium-sized companies account for 99% of the companies in Japan and hire 71% of the workers
  • Japan imports 99.9% of fossil fuel energy sources
The most interesting point was the idea that customers are looking for "Shohin", not product.  Shohin = Product + Following Service.  What this means is that you don't just list the features of the product, but show what that means graphically and make the specific customer benefits explicit instead of using vague statements.

Most of the study group didn't think that Aichi Sangyo was a good example of a Lean manufacturing company but I figured they were more of an engineering firm and they have managed to keep going for 71 years which is quite an accomplishment.

----
In the afternoon we continued to Toto Bath Create, the division of Toto that produces what are called unit bathrooms.  Toto reminded me more of what I've seen before from previous site visits organised by the Lean Network.  A lot of the emphasis is on 5S, kaizen, and training.  This was also the first place I encountered one-point lessons, though I'm sure it's nothing new for manufacturing types.

Most interesting point was Toto's distinction between two types of kaizen:
  • C Kaizen - Change, Control, Communication, Challenge - refers to "improvement by ourselves in daily life"
  • D Kaizen - Dynamic - refers to large company-scale improvements
I think this is equivalent to point kaizen vs process kaizen.

It's not an issue of purity; it's an issue of being lazy

"Maybe a pure form of 'Agile' isn't appropriate for that team, in their context."

The problem has never been about whether teams are "pure" enough; the problem has always been an issue of complacency and laziness.

Actually, I don't know if laziness is the right word, but it's the attitude that we'll just do the things that are easy for our context and hope that the rest will just work itself out.  It won't.  And if you're paying attention, the world has become significantly less forgiving about that.

Saturday, November 15, 2008

John Shook on pull-based authority

I've encountered a common perception, even amongst people in the Agile or Lean community, that positional authority is required in order to change anything. At the last Lean Summit Australia, John Shook corrected that perception. Now that he's started blogging, there's an entry I can reference the next time I'm told that "we can't succeed because we don't have enough authority":

Individuals in a lean management system take initiative to gain authorization to implement their ideas, manufacturing the authority they need when they need it: on-demand, just-in-time, “pull-based authority.” You will find no more appropriate occasion to exercise initiative, no better place to start than … right here and right now.

If you're looking for easy, look elsewhere

James Shore on why Agile is not just a 2 day certification course:

Or maybe we need to stop selling Agile. Maybe we need to say, "Agile is hard, and you can't master it by sitting through a two-day course." Maybe we need to be firm and say, "Sorry, if you don't use agile engineering practices, if you don't have high-bandwidth communication, and if you don't include a strong customer voice, you're not going to succeed. Try something else instead." Scrum is popular because it's easy--and that's part of the problem.

Sunday, November 09, 2008

No pain is a big pain

Kind of odd writing "No pain is a big pain" while I currently have a headache but Martin Fowler blogs an important point about Agile and Early Pain:

A few years ago I was talking with a client who told me something he didn't like about the agile approach we were using: "it's doesn't feel right to have these difficulties this early in the project". Contrary to his reaction, in my mind this early pain is one of the great benefits of an agile or indeed any iterative development process.
In Toyota circles there's a phrase: "No problem is a big problem".  The point is that in any system there are always problems so that if people are saying that there are no problems, then we have a bigger problem that people don't know how to see, or worse, that people are hiding problems.

So... assuming all project have difficulties and that it is cheaper to deal with difficulties earlier in a project, then if I don't experience early pain on a project, then I have a larger pain to deal with.

Standing up means less effort to go walking

Kevin Meyer at Evolving Excellence blogs about stand-up vs sit-down desks:

The companies cited several reasons for standing at desks, including the same health and ergonomic improvements mentioned above.  But they also mentioned one other critical attribute of people that stand: it takes less energy for them to go walking, to the gemba for example.  These people would immediately go and see what was going on, address problems faster, and be more efficient.

Tuesday, November 04, 2008

Effective detection is good; effective prevention is better

It's important to know when a defect occurs.  That's what inspection (aka testing) is for.  Inspection is non-value added activity but it is necessary to prevent leaking defects to your customer, whether that's the next process step or the end consumer.

Don't forget though that knowing when a defect occurs doesn't help you prevent defects.  For that you need to know how and why.

Agile practitioners will typically respond to a defect with "What kind of test can we write to catch these types of defects?".  This is good.  But it's better if we first ask the question "How can the system be designed such that these type of defects can't occur?"

Effective detection is good; effective prevention is better.

Saturday, November 01, 2008

This is not about scoring the most points

If you use # of story points to set a target line, you must be wary about forgetting that the goal is not # of points done.  If you can work out how to achieve the business goal by doing less points, that is better.

The is not about scoring the most points; this is about winning the game.