Our most recent two days (Thursday and Friday) have been spent learning at Yamaha, Honda, and Aisin. We saw Yamaha and Honda make motorcycles and watched Aisin manufacture car parts and mattresses(!!). With each succeeding visit we are experiencing better and better examples of efficient systems and worker supports, and we are improving our ability to "see" them. I am sure it is hard to believe but, though we have been here over a week and spent countless hours at several factories...we are still highly engaged and yes, still excited to be here. We are learning a lot.
The trip senseis and organizers (Shingijutsu Global Consulting and John Black, LLC) have cleverly arranged our visit so that each successive company is leaner than the last, and the experience has literally been inspiring. These companies have achieved so much that it sometimes feels beyond our reach to emulate them, but we see practical applications for Children's everywhere we look.
Our sensei have helped us understand and see lean principles at work in the factories (and one office operation) we visited, but it is up to us to apply them in our world.
Here are some thoughts from team members about how they think lean can be applied in their areas:

Lynn Stapp, Microbiology team
"I would like to apply the teachings of the sensei to enhance the flow in microbiology. Some things to try are visual controls for quality (e.g., visuals for specimen collection); removing flow bottlenecks (e.g., provider notification difficulties); and enhancing our mixed model line (e.g., mixed versus pure cultures)."

Sarah Thomas, Clinic
Referral and Scheduling team
"Our sensei stressed the elimination of "muda," or waste, to support flow. Elimination of the "muda" of rework in scheduling will improve our ability to manage our growing volume of calls."

Darren Migita,
General Medicine Team
"We have learned a lot about lean priniciples like "outside flow" and "inside flow." What these principles come down to is enabling people to do the best job possible by bringing supplies and equipment to them--right item, right time, right place--to support the care of patients. The "outside flow" of equipment and supplies is critical to the "inside flow" of patient care."

Glen Tamura,
General Medicine Team
"When the workload goes up, we tell our doctors to just run faster and our patients to wait longer. We have seen how companies have effectively matched workforce to workload through the principle of heijunka. Our patient activity is both predictable and predictably unpredictable, and by using the load leveling principle of heijunka we can do a better job of responding to changes in workload."

Barb Bouche,
Microbiology Team
"I have been able to see, with each successive factory visit, that "kaizen"--continuous improvement--is not an add-on to the work; it IS the work. The improvements can be seen and felt. It is truly amazing, and has inspired all of us."
On a personal note, all of us have thoroughly enjoyed and learned a lot from the three sensei from Shigijutsu Consulting and John Black. They have brought a rigor and discipline to our studies that would have been impossible to achieve without them.
More in a day or two...
Comments (2)
I've been fascinated by the reports from Japan about lean principles. One small thing that jumped out at me was in Sarah Thomas' report on "muda" -- waste. In German, the word "muede" (pronounced: muda)means "tired." And wasted effort does make us tired, doesn't it? Many thanks to all of you for sharing your impressions. Cheers from home, Caity
Posted by Caity Gerhardt | June 25, 2007 8:39 AM
Posted on June 25, 2007 08:39
I too find all the reports fascinating. In particular, how the senseis organized your trip so that you were able to see organizations from least to most lean. I'm sure this gave you a great perspective on how an organization changes as lean principles are applied. I look forward to speaking with some of you about what you observed in the lean office you visited. Until then, 安全な旅行を持ちなさい (have a safe trip).
Posted by Nabeel Khan | June 28, 2007 12:03 PM
Posted on June 28, 2007 12:03