Page 116 - How To Implement Lean Manufacturing

How to Do Lean—Cultural Change Fundamentals 95

book by Keki Bhote entitled World Class Quality (AMA, 1988). If you want to pick up this
book, do an out-of-print search and try to find the first edition if possible. It’s superior
to later editions and usually less expensive, as well.

Which trainings to do first? The following three are a must!

• Kepner-Tregoe problem solving (clearly the #1 choice)
• Statistical problem solving (such as Six Sigma or at least DOE) is a must
• Group facilitation training

It would be good if one or more of your group of problem solvers was an accom-
plished Six Sigma Blackbelt, and if one or more had strong group facilitation skills and
were skilled and experienced enough to do a facilitated “spin-around” on a broad vari-
ety of problems (described in the accompanying sidebar).

Brainstorming Rules, the Facilitated Spin-Around
The facilitated spin-around is a very powerful way to gather information and resolve
several types of problems. For many data-driven, on-the-line production problems, this
is not a good technique, however. First, it is normally not needed, second, it simply takes
too long. It is good for issues with “soft data,” such as opinions and for decisions that are
emotionally charged, such as “should we require all employees to wear a uniform?” It
is a technique that will reach very good decisions, but more importantly, because of the
process itself, the members will have a strong commitment to implementing the group
decisions. The facilitated spin-around is often required to reach consensus. It is critical
that your organization be able to use these techniques and have facilitators capable of
leading these groups. The technique goes like this:

1. The facilitator introduces:
a. Himself
b. The topic very briefly
c. The objectives of the group
d. The agenda
e. The planned timeframe for this meeting
2. If meeting ground rules need to be discussed (such as cell phone use,
bathroom breaks, and so on), this is done at the beginning.
3. The facilitator reminds them of the brainstorming rules, which are:
a. One item per person per turn.
b. Each person in turn (hence “spin-around” the room).
c. The documenting and posting of each item is done on flipcharts.
(I recommend you use flipcharts. They are much more personal than
using a computer projected onto a wall.)