Category Archives: Innovation

How to Design a Poka-Yoke

Our previous post defined a “poka-yoke” as a means of mistake-proofing a product or process.

The question is, how might we best go about designing these fail-safes?

To begin, poka-yokes must be devised to prevent a particular type of error, which is why it is so important to thoroughly study the problem, the process, and the root causes. Once you have all the facts and data about what is going wrong most often, in what way, and why, you can set your collective creative minds to designing a poka-yoke that most effectively and efficiently prevents the most frequent human errors or omissions.

Yet a simple and powerful poka-yoke is almost never the first solution a team comes up with.

The best ideas take creativity, collaboration, and the time to press on past the weaker solutions that come to mind first. Most often, the first idea  ― which, as noted above, almost never represents the best solution ― is one of the following:

  1. Ask people to be more careful
  2. Ask management to send an email telling people to be more careful
  3. Schedule a training session in which people are instructed to, yes, be more careful

These solutions might help for a little while, but improvement is fleeting.

Instead, armed with a thorough understanding of the process and how things go wrong, you must keep brainstorming ideas until you can find a way to inexpensively make it much easier to do the work right or at least automatically alert a person when he or she has just made the mistake.

In addition, people often progress through weaker controls to progressively more effective poka-yokes. For example, one garage progressed from a weak control ― a warning sign stating ‘No vehicles higher over 7 feet high’ ― to a bar at 7 feet, which when pressed set off flashing lights and warning sounds. Eventually, they had an inexpensive laser beam which when broken would trigger an arm to fall, blocking entry. No more difficult extraction of vehicles that exceeded the height limit!

Learning from the Marketplace to Promote Internal Change

As noted in our previous post, “knowledge” is one of the most powerful change agents, and all sorts of learning can become a catalyst for change.

One very effective source of knowledge is our marketplace, which includes our customers and competitors.

By learning from the market we can often see possibilities for innovation that have been overlooked. Of course learning is only the first step, as the gained knowledge must then be applied.

For example, in the early 1980’s, Toyota believed that to grow their sales in the United States they would need to have manufacturing facilities here, but they concluded they did not have enough knowledge to do so successfully. So they entered into a joint venture with General Motors, opening the NUMMI plant in California to produce both the Chevy Nova and the Toyota Corolla in the United States.

After they achieved their learning goals, Toyota went on to successfully open plants in a number of U.S. locations, applying their knowledge each time.  While General Motors had the opportunity to learn the production systems that enabled Toyota to produce very high quality products at low cost, and while many individuals at GM learned a great deal through this venture, GM gained little more from the venture than the cars that came off the assembly line.

Learning from the customer can also open our eyes to new possibilities. But it’s important to recognize that customers may tell you what they want, but not necessarily why.

So making the extra effort to go beyond just “what they need” to gain knowledge is critically-important. Contextual inquiry is a method of learning more about the customer needs than the customer could tell you by watching the customer use the product in context.

What do they really value? How do they use or struggle to use what you give them? What are the things that you could do differently that the customers would not know to ask? And consider that they don’t ask because they don’t know enough about your process
to suggest it, and you don’t know enough about their process to offer it!

Similarly, knowledge of the competition can produce a greater sense of urgency or a heightened “willingness” to change, and in many cases can give us better insights as to the best ways to satisfy our customers and achieve a competitive edge.

Leading a Culture of Innovation & Continuous Improvement

Tying recent posts together, and spring-boarding off a good comment shared about “the biggest waste lying in the ranks of poor leadership,” this post focuses on the critically-important role leadership plays in developing and sustaining a culture of innovation and continuous improvement.

Simply stated, given the challenges of creating a consistently effective innovative organization, nothing is more important
than leadership.

It requires powerful leadership skills to empower and unleash an organization’s creative talents and energy. In an organization without strong leadership, inspiring and empowering people to contribute their ideas innovations will be scarce. An innovative culture is not the default position — it must be carefully created.

But empowerment, important as that is, is nowhere near enough.

Leadership must also create a challenging vision around which to rally the organization’s creative energies. This vision must be grounded in a deep understanding of the market and of the daily struggles of the people who make up that market.

Understanding the market is much easier for a small company where everyone deals with real customer needs every day. But as organizations grow, they expand like a balloon — more mass and less surface area. The surface area has the chance to get close to the external customer’s needs.

So, as a company grows, leadership must maintain or create a mechanism that will ensure that an  understanding of the customer’s needs can penetrate beyond the surface area into the heart of the organization. The same is true of internal functions that work together like a chain of customers. As organizations grow, departments grow and they too develop ‘more mass and less surface area’ — creating the familiar silo phenomenon.

In addition, leadership of innovative organizations must, without stifling creativity, challenge the organization’s efforts with the necessary, market-driven constraints. Without the right constraints,
empowerment cannot succeed. It is too easy to become satisfied with a creative idea before it has been developed into something really workable. An organization that tries to empower innovation without creating the right market-driven constraints, can easily suffocate in an avalanche of incomplete or impractical ideas.
Because they are not fully developed to address the real, but perhaps unspecified, constraints, the ideas cannot be implemented and quite soon people cease to feel empowered.

This is a tall order, and it becomes easy to see why innovation isn’t easier to come by despite all the human talent and energy brought to bear. But creating an innovative culture is, in itself, a creative challenge. By increasing our understanding of the challenges and constraints, we increase our ability to focus our own leadership talents on the right things to make it happen.

Silo Treatment?

Bill Conway always said, “The biggest waste is found in the interfaces and interstices.”

Or, said another way, the waste is found at the seams of the value stream as it crosses  different organizational boundaries, which are often referenced as the “silos” in which many of us work.

Some time ago, we were involved in an exercise in streamlining office work and had set up an order processing operation that had lots of obvious waste analogous to the sort commonly found in office processes. The simulation was conducted a number of times, usually in one large room with different departments in different areas of the room.

Participants were always able to identify large amounts of waste, because it really is much easier to see waste in someone else’s process than in one’s own. The simulation helped participants to see the waste and then to draw analogies to opportunities they had overlooked in their own work. So light bulbs would go on and participants would generally be able to redesign the process to increase throughput up to ten-fold!

Then one day, the training facilities were different: no large room, just one mid-sized room and a number of breakout rooms.

Even more realistic, we all thought… the Credit Checkers were in one room, the Order Processors in another, and so on.

But when we reconvened to debrief, everyone seemed oddly comfortable with the whole process they had been executing. They identified little things they could improve within their small group, but they missed the elephant in the room — perhaps because it was in next room, or rather the hallway where no one owned it.

As Bill always said, the big waste was in the “interfaces and interstices… and, as noted in a previous post,  “It is easiest to think outside the box, when you are from outside the box” (or silo!).

Innovation & Cross-Functional Collaboration

Continuing with the theme of innovation, the breakthrough process innovations that achieve order-of-magnitude improvements almost always require cross-organizational collaboration.

So it’s not surprising that this level of innovation is difficult to achieve because, while cross-organizational improvement efforts present substantial opportunities, they also pose some formidable obstacles.

Three of the most common barriers to cross-functional success, along with some ideas on how to overcome them, are:

Too many people… One of the basic facts of accomplishing cross-organizational work is that we must involve more people.  This size factor alone can make the project more difficult to execute. The larger the group, the more effort is required to ensure that good working relationships develop among the team members.  Scheduling meetings becomes more difficult, and individuals may take less responsibility because with a large group it is easier to assume someone else will pick up the slack.

To better-manage larger project teams, leaders must pay close attention to organizational tools and methods, such as forming a proper charter, clearly-defining roles, maintaining consistent communication with top management, scheduling meetings well-in advance and on a regular time-table, distributing meeting agendas in advance to promote awareness and preparedness, and adhering to effective meeting management protocols.

Cumbersome logistics… Cross-organizational improvement projects frequently involve multiple locations, different time zones, and different cultures. Not only can these factors pose scheduling challenges, but also bring about issues with respect to team-building and communication.

To overcome or minimize these challenges, leaders can schedule the initial meeting in person and invest in intensive team-building up front.   For remote meetings, they can add interactive visual communication and employ a more interactive facilitation style; scheduling can “rotate” to accommodate different time zones as well.

Conflicting priorities… The biggest impediment to accomplishing cross-organizational improvements is the power of competing priorities, which can make it hard to form an overall consensus or gain buy-in to the overall mission and vision.  The danger of shifting priorities is many times larger with cross-organizational projects as well, making it more likely that new urgent demands will arise before the project is complete, and resources become overloaded and start missing meetings and skipping action items.

To address these challenges, leaders can begin by conducting a thorough analysis that highlights the enterprise-wide benefits that are at stake. Engaging top level sponsors is also a must. While sponsor engagement is essential to the success of most change efforts, it is more critical for a cross-organizational improvement project. It is also important for all parties to respect the inevitable differences in priorities and operation models, and to avoid the appearance of being judgmental or of telling others “how they should be doing their jobs.”

Finally, nothing succeeds more than success! Achieving some quick wins, and sharing the details, is a great way to start.  Successfully addressing chronic problems is especially great for keeping people engaged and ready to do more. Facilitators are also sales people for the facts, data, methods, and for getting buy-in for the team’s recommendations.  But be sure to leverage every success to encourage more participation.