In Other Words…Off-Shoring Was Carried Out by Dumb Managers

Here’s an interesting paragraph I ran across in my recent reading ramblings:

“For instance, it was assumed that assembly labor was the significant, intractable piece of the pie, one that could easily be transplanted to foreign shores at great savings. Actually, that category of labor averages closer to 4-5 percent of product cost. Finished materials consume roughly 70 percent and overhead another 24-25 percent.

Piece parts were the very tip of the iceberg that somehow went to bid and largely decided overseas deals. This left behind fixed assets in plants, the same management overhead, increased travel, new customs fees, and greater outlays for logistics. Insufficient quality and time-to-market penalties were the other giants hiding under the waterline of standard accounting. Rarely were these factors assessed and attached to the part or assembly of parts under bid.”

via How An Old Analysis Technique Could Strengthen The U.S. Manufacturing Revival – Forbes.

I think this is a nicer way of saying:

“Much off-shoring was undertaken by managers who didn’t know what the hell they were doing.”

Full Disclosure about Book Reviews

From time to time, in my posts, I’ll mention books I’ve read.  I also do book reviews.  Generally, I provide links to Amazon in case a reader wants to purchase the book right then and there.  Well, it turns out that, by joining with Amazon affiliate program, I can get a small commission (4% up to 10%) whenever somebody does this. I figure I’ll make about $10 a year this way…if I’m lucky.  But I also figure there’s no downside.

Why do I bother to mention this?  If I’m making money from something you do (buying a book from Amazon), you should know about it.

OK, that’s it for barely relevant news…back to the good stuff.

A Lean Manufacturing Mind-Set

I genuinely try to put myself in the shoes of the supervisors and managers I work with.  They have lots to do, they’re under a variety of pressures, and I’m not the first guy who’s come around promising that their work lives will change dramatically for the better if they’ll just put my ideas and lessons into practice.  I make a concerted effort to understand their circumstances as I ponder why implementations often go slowly….sometimes VERY slowly…in spite of my sustained attention, not to say outright nagging.

That said, I sometimes get frustrated with those same supervisors.  Even supervisors and managers who seem to be genuinely open to my coaching and advice often move very slowly in implementing them.  I’ve come to the conclusion that a “lean mind-set” is not common among manufacturing managers and supervisors.

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Really Bad Article on Lean

I often go on (and on) about the fact that much (perhaps, most) lean literature isn’t very good.  It too often tends to be boring, cliche, repetitive (if I have to read or hear about Eight Wastes one more time…), shallow…did I mention repetitive?

But little of the literature in lean is as bad as this article (I hesitate to link to it because, I gather, that gives it some “Google credibility”, i.e., more folks are likely to find it via web searches.  But, here goes…): The Secrets of Lean at The Lean Post.

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Lean Manufacturing Provides Transformational Value: Part 2

In my last post on this topic, I wrote the following:

“These new capabilities and capacities should compel the organization to use that new capability and to fill that new capacity with.  I say “should” because it doesn’t always happen that way.”

As I’ve mentioned many times here, organizations get stuck on the idea that lean principles just cut costs and waste. They don’t consider or aren’t open to the notion that lean actually adds capacity and capability…the capacity and capability to do something that couldn’t be done before.  In effect, companies are required to answer, for themselves, the question:

‘If we weren’t doing what we’re doing today…what would we be doing?”

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Lean Manufacturing Provides Transformational Value: Part 1

I’ve got this friend who’s made a few million (I think) in business software development.  He’s a smart guy and we have fun discussions about business and politics (we think a lot alike on both).

sum of partsRecently , he was onto something that I actually took notes on.  He used an illustration:  Let’s say one guy knows how to make chocolate and sell it and does a great job at it.  Another guy knows how to make peanut butter and he does a great job, too.  Then there’s a third person…this guy doesn’t make anything but he has this idea as to how the chocolate and the peanut butter can be combined to make a product that nobody ever saw before and that everyone will love.  Which of the three stands to add the most value to shareholders, to the employees of the two companies, to society?  Why it’s that guy with the idea, right?  My friend referred to this as the idea that provides transformational value.

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How to Implement Lean Manufacturing – Strategy and Spread the Word: Part 2(a)

I don’t like to have blog posts that have “Part 2(a)” in the title.  It’s just…I don’t know…persnickety or something.  But I did want to add a word or two (or…couple of hundred) about Spread the Word before moving on.  Specifically, I wanted to add something of a list of Spread the Word activities an organization starting a lean implementation should engage in.  I mentioned a few of these activities in my earlier post, but a re-reading of it prompts me to expand and elaborate.

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Lean Manufacturing Isn’t The Tools

I’m putting together a short training program for something I’ve done a lot over the years, 5S.  One of my issues is that most of the reading I’ve done and training I’ve seen on 5S simply digs into the easiest, “toolsy” part of it.  You know…first you Sort, then you Set in Place, then you Shine, and it provides a safer more productive workplace.  What’s not to like, right?

Well, very little of what I’ve seen really digs into the core raison d’etre of 5S.  What’s it really, down deep for?

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