Publishers send me a lot of books, magazines, etc., and I’m thankful for all of it. Understandably, I can’t and won’t read everything I’m sent. From time to time, I do receive a book for which I’m excited. This is one of those times.
Last week, my copy of Jim Womack’s Gemba Walks arrived at my house. I’ve read through some of it already and I am really enjoying it. I highly suggest this book to the lean practitioner, learner, and newcomer.
As a reminder, I wrote an article about 4 years ago that explains a little bit about what “Gemba” means in the context of lean manufacturing entitled The Gemba is the Dojo.
John Shook, the current CEO of the Lean Enterprise Institute, provides a great introduction to the book, which I cite here:
“The first time I walked a gemba with Jim was on the plant floor of a Toyota supplier. Jim was already famous as the lead author of The Machine That Changed the World; I was the senior American manager at the Toyota Supplier Support Center. My Toyota colleagues and I were a bit nervous about showing our early efforts of implementing TPS at North American companies to “Dr. James P. Womack.” We had no idea of what to expect from this famous academic researcher.
“My boss was one of Toyota’s top TPS experts, Mr. Hajime Ohba. We rented a small airplane for the week so we could make the most of our time, walking the gemba of as many worksites as possible. As we entered the first supplier, walking through the shipping area, Mr. Ohba and I were taken aback as Jim immediately observed a work action that spurred a probing question. The supplier was producing components for several Toyota factories. They were preparing to ship the exact same component to two different destinations. Jim immediately noticed something curious. Furrowing his brow while confirming that the component in question was indeed exactly the same in each container, Jim asked why parts headed to Ontario were packed in small returnable containers, yet the same components to be shipped to California were in a large corrugated box. This was not the type of observation we expected of an academic visitor in 1993.
“Container size and configuration was the kind of simple (and seemingly trivial) matter that usually eluded scrutiny, but that could in reality cause unintended and highly unwanted consequences. It was exactly the kind of detail that we were encouraging our suppliers to focus on. In fact, at this supplier in particular, the different container configurations had recently been highlighted as a problem. And, in this case, the fault of the problem was not with the supplier but with the customer – Toyota! Different requirements from different worksites caused the supplier to pack off the production line in varying quantities (causing unnecessary variations in production runs), to prepare and hold varying packaging materials (costing money and floor space), and ultimately resulted in fluctuations in shipping and, therefore, production requirements. The trivial matter wasn’t as trivial as it seemed.
“We had not been on the floor two minutes when Jim raised this question. Most visitors would have been focused on the product, the technology, the scale of the operation, etc. Ohba-san looked at me and smiled, to say, ‘This might be fun.'”
It’s a great book to add to your lean library. Go get it. Here’s the book’s official description:
The life of lean is experiments. All authority for any sensei flows from experiments on the gemba [the place where work takes place], not from dogmatic interpretations of sacred texts or the few degrees of separation from the founders of the movement. In short, lean is not a religion but a daily practice of conducting experiments and accumulating knowledge.
So writes Jim Womack, who over the past 30 years has developed a method of going to visit the gemba at countless companies and keenly observing how people work together to create value. Over the past decade, he has shared his thoughts and discoveries from these visits with the Lean Community through a monthly letter. With Gemba Walks, Womack has selected and re-organized his key letters, as well as written new material providing additional context.
Gemba Walks shares his insights on topics ranging from the application of specific tools, to the role of management in sustaining lean, as well as the long-term prospects for this fundamental new way of creating value. Reading this book will reveal to readers a range of lean principles, as well as the basis for the critical lean practice of: go see, ask why, and show respect.
- why companies need fewer heroes and more farmers (who work daily to improve the processes and systems needed for perfect work and who take the time and effort to produce long-term improvement)
- how good people who work in bad processes become as bad as the process itself
- how the real practice of showing respect comes down to helping workers frame and solve their own problems
- how the short-term gains from lean tools can be translated to enduring change from lean management.
- how the lean manager has a restless desire to continually rethink the organization’s problems, probe their root causes, and lead experiments to test the best currently known countermeasures
By sharing his personal path of discovery, Womack sheds new light on the continued adoption and development of the most important new business system of the past fifty years. His journey will provide courage and inspiration for every lean practitioner today.