“I don’t have time”

The great dividing line between success and failure can be expressed in five words: I did not have time.– Franklin Field

Over and over, after running through a problem solving session or providing training on proper job instruction, I’ll hear, “It sounds great and I think it will work, but we don’t have the time,” or something like that. Despite overwhelming evidence, including actual demonstration of the new method or technique, company executives retreat behind the well worn excuse of being too busy to make any real change. Well, if the new method or technique sounds great and it does work, then why aren’t you doing it? If it’s because you claim that you don’t have the time, then I have to ask: What on earth are you spending your time on?

Some of you are wondering who the heck am I, casting even a shadow of a doubt on what you do with your time.  “Who does he think he is? What does he know about what I do?” As it turns out, I know a lot more than most outside observers because, you see, I’m one of you. I’ve run small, independent shops with 20 employees, and large, corporate, 24/7 operations with as many as 200. As the expression goes, I’ve “been there, done that.”

It’s not enough to be busy, so are the ants. The question is, what are we busy about?– Henry David Thoreau

Back in my plant manager days, I once had a colleague call me “the world’s most expensive customer service rep.” I was spending an inordinate amount of time on the phone with irate clients, sales managers and sales representatives, playing Three Card Monte with the day’s production schedule. He was right – I was the world’s most expensive customer service rep because I wasn’t doing my job of being a plant manager, which was to lead the plant.

When I look back at that period in my career I can now see so many things that I had been doing wrong: all of the tasks and activities – the daily grind – that I had thought amounted to time well spent but were, instead, a complete waste of my time. I was running around fighting fires and trying (sometimes unsuccessfully) to prevent conflagrations. I was “busy about” all of the wrong things but thinking that, because I was busy, I was doing my job. What I didn’t realize, though, was that I was constantly extinguishing the same fires, day in and day out. I suspect that most of you are doing much the same and, like me, doing so without realizing it. In other words, you’ve become me – the world’s most expensive customer service rep.

In truth, people can generally make time for what they choose to do; it is not really the time but the will that is lacking.– Sir John Lubbock

We have plenty of time for continuous improvement; we just don’t make the effort to use our time wisely. Instead, we spend our time running (sometimes actually running) from emergency to emergency and then we tell ourselves that we’ve done all that we can to fix whatever the emergency was because we’ve spent so much time on it. We’re kidding ourselves, even deluding ourselves, into thinking that way because we just don’t have the will to confront the real challenges that our jobs require us to confront each and every day. We shouldn’t be focused on firefighting; we should be making our facilities and our processes fire proof.  We shouldn’t swoop in like Superman to save the day but, rather, we should be teaching others the requisite skills to prevent Gotham from falling apart.

Our roles as leaders shouldn’t be cleaning up the mess that’s left behind in the wake of the SS Disaster. Our role should be to steer our ship and to lead our crew to the next port of call and beyond. If we’re always in the engine room making stop-gap repairs to keep the ship sputtering along, we’ll never be able to see where the ship is headed, and we’ll likely run aground. We think we’re the Skipper, but we’re really Gilligan, fumbling our way from chaos to catastrophe.

We’ve all seen or heard some variation of the expression, “There’s never time to do it right, but plenty of time to do it over.”  We all think that it pertains solely to quality of our products but it pertains to the quality of our time, too. We all get frustrated, even angry, over the wasted time (and material) when something that we’ve produced gets rejected, but we never seem to get upset over the time that we waste on everything else.

How many times have you become frustrated or upset that a meeting doesn’t start or finish on time? Well, did you spend your pre-meeting time wisely and properly plan for this meeting? Probably not so, once again, the fault lies how you chose to spend your time (not) planning for the meeting.

Have you ever walked around your facility and became frustrated or angry over how much inventory you have, thinking of all of the cash that’s tied up in that inventory? Why is that inventory there? Who purchased that much raw materials or ran that much product? Who took the time to plan out how much was really needed? My guess is that no one did. Do you control your inventory or does it control you? If you’re not spending any time planning your inventories, your ins and outs, then your inventories are controlling you.

And what about the wasted time and material when something was produced and then rejected? Did you spend any time uncovering the real root cause or did you, like most, knee-jerk react into the stratosphere and blame the operator, supervisor, quality control department, the sun, the moon and the stars? Does the operator who ran the material really know what to do? Again, I suspect not, because most operators are poorly trained before they’re thrown into the fire. And why are they poorly trained? Wait for it. Wait for it. Yup, you guessed it. You don’t have the time!

You will never find time for anything. If you want time, you must make it.– Charles Bixton

Your time is yours to do what you want. If you’re not spending your time doing the right things right and, instead, choose to fight fires instead of preventing them, then the responsibility for the conflagration that ensues rests entirely with you.

Make the time. It will be well worth the investment.

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The Value of a Value Stream Map

My latest column for Label and Narrow Web magazine is about the much maligned and misunderstood value stream map.

Everything you do, from door to dock, is what makes up your value stream.

A key tenet of Lean, it is often said, is the complete elimination of waste. Waste is anything other than the minimum amount of equipment, materials, parts, and time that is absolutely essential to provide the customer with what they’ve requested. Sounds simple enough, but unless you’ve been trained to see waste, you probably cannot.

In the October 2007 issue of Label & Narrow Web, I wrote about value streams and the value stream mapping tool. I called these maps “treasure maps” because they can lead you to the waste that’s hiding in your value stream. Your value stream is everything that you do to bring your customer orders from receipt to delivery. That means everything, and everything that you do costs money. Finding money that you don’t have to spend is like finding buried treasure.

It’s not about the equipment
Many printing companies and company executives don’t believe that a value stream map is of any use to them. After all, printing isn’t about making planes, trains or automobiles. Print companies, they say, are job shops where every day brings something different, and their entire value stream is contained on just one or two pieces of equipment: the press and, sometimes, a slitter rewinder. These arguments against value stream maps show just how uninformed so many are about this tool. This article, then, is for you.

A value stream map is not simply about the equipment. After all, there’s so much more to your operation than just a press. The press doesn’t take the customer’s phone call, does it? The press doesn’t preflight the customer’s artwork, does it? No, people do these actions, and many more, and anywhere that you have people performing any type of work you have components of your value stream. So it’s not just about the equipment.

The argument that print companies are unlike other manufacturers, in that the jobs we run are different every day, is really a false argument: The only difference between today’s job and tomorrow’s job is where the ink is distributed on the substrate and the shape of the diecut. You’re still using ink, plates (except for digital printing), substrate, and a cutting die; you’re unwinding stock through the press and rewinding it. In short, we do the very same activities every single day, so we are very much like an automobile manufacturer who makes many different models of cars using the same equipment and the same assembly lines day after day.

It’s about everything that you do
In order to see the waste in your entire value stream, you must first understand just what that value stream is. In short, it’s everything. Everything that you do from the moment your customer places an order to when you finally deliver the entire order is what makes up your value stream. The value stream map helps you to visualize these activities so that you may begin to see where you are using more than the “minimum amount of equipment, materials, parts, and time” to get that product to the customer. Without having this information you’re just guessing and probably guessing wrong, very wrong.

Go see, ask why, show respect
When created and used correctly, value stream maps provide the information that you need not to help you guess, but rather to make informed decisions about where you’re wasting time, material and money – and where you’re not. Getting this information is more than just walking around, pointing and asking questions.

Former Toyota Chairman Fujio Cho once said that when a manager is looking to discover answers, then he or she needs to “Go see, ask why, show respect.” Go to the actual place where the work is, ask why its happening the way that it appears to be, and always show respect to those whom you’re asking the questions of because it is they, after all, who are doing the real work and not you. They know why, you don’t.

When you ask why and then follow up on the answer, you begin to uncover root causes. Without asking why and without doing so out in the customer service office, prepress, or shop floor, you can’t find the root cause. Every time that I lead a team out into the value creating areas, they are amazed at what they find. I hear a lot of “I didn’t realize” or “I didn’t know” and that’s because people don’t take the time to go see, ask why and do this with respect. Whenever they go see it’s usually to demand why and assign blame.

You don’t know Jack
A value stream mapping session is an eye opening experience. It can also be a humbling one. You may think that you know exactly how your customers’ orders get from door to dock, but unless you’re answering the phone, creating the order, buying the material, preflighting the art, making the plates, mixing the inks, setting up and running the press, slitting, packing, shipping and invoicing the order, then you’re just guessing. And, since you’re guessing, the real blame behind why things are they way they are rests entirely with you, because it’s your business.

A value stream is everything
Remember, it’s more than just the equipment.  Your value stream map tells you every single activity that your company does to get product to your customer whether you want every single one of these activities to happen or not. They’re happening, you need to see them happening, you need to understand why they’re happening, and you need to stop those activities that are waste from happening. It’s that simple.

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