Rules for Achieving Production Goals

Knowledge Check!Some may scoff, others may scowl, but I will tell you an open secret, if you are not quality first, production goals will never be achieved.  Sure, a company may hit a target now and then, of course a quarterly statement might come in on target, but reliable production cannot be achieved without quality focus and the following rules.

With more than 20 years’ experience in manufacturing, supply chains, logistics, call centers, and much more, the following production rules are at least a moment of your time for reading and two moments for consideration.  Yes, there are a lot of people who will claim they have the path to success mapped and if you follow it, you to can achieve success.  I am not one of them!  I have tried and true lessons, I have common sense approaches, and I offer freely information that when combined with your knowledge, and the people you have working for you, solutions can be generated to achieve success.

  1. Quality is everyone’s job! – Tell me; whose job is it to pick up trash in the parking lot? How much litter is in your parking lot, trapped against the fence, collecting around the dumpsters, and crowding the floors of your facility inside and out?
    • A colleague states the following:
      • I can tell you within five seconds after arriving the quality mindset of the facility I am visiting, by looking at the parking lot.”
    • My colleague is correct; every facility I have visited that has had a clean parking lot, where employees and managers are picking up after themselves, has a quality culture worth emulation. Unfortunately, the reverse is also true!
    • What does your parking lot look like?
  2. Never take your customer, employee, shareholder, vendor, etc., where YOUR brain has not traveled first! – I sat in a meeting where the leader openly admitted, after telling the new strategic focus, goals, and mission plan, when answering questions about this plan regarding implementation, stated, “I haven’t thought that far ahead.” That company is bankrupt.  Not because they did not have good products, customers willing to buy, or great service, but because the leadership took the business places they had not personally already traveled in their minds.
    • How can you expect any goal to be achieved if you cannot answer implementation questions?
    • How can people follow if you do not know where you are headed?
    • Where are you going and has your brain already traveled there?
  3. Data will be misinterpreted if specific explanations are not included! – New manager, fresh from school, knew all the lingo, had all the buzzwords memorized, was handed a sheet of data, and failed to comprehend what the data meant. Worse, he led others into ruin by misinterpreting data.  If data is not explained, if the why behind data is not clearly understood, if the data story is incomplete, the data is useless, meaningless, and valueless!
    • What is your data story?
    • How do you train others in your data story?
    • Can other people explain the why behind the data, or do they have to come to you for that explanation?
  4. When in doubt, trust your people! – Time does not allow me to relate even a tenth of the stories where the people have proven the data wrong, have gone above and beyond expectations, and achieved miracles. Yet too often the people are the first ones cut in a crisis.
    • Juran’s Rule – When something is going wrong, 90% of the time it is the process, not the people. Yet, how many times are the people blamed for bad processes?
    • Appreciative Inquiry – The theory that states that when you have a problem, the people already in the positions doing the job, hold the answers needed to fixing the problems. Yet, how many times are the people the first one’s lost in crisis?
  5. Data lies; humans live! – Recently the data stated that the problem in a facility was in a specific area. The specific area was encouraged to perform better.  The management thought, “Problem solved.”  Production goals were missed, more counseling to this specific area, more encouragement to achieve, more focused spending to target pain points.  Still missed production goals.  Nobody looked beyond what the data said was the problem, and the data was suffering from a pretty severe case of GIGO (Garbage In = Garbage Out).  There was no production goal problem in the area specified, the problem was on the other side of the plant, and because of the investment in the wrong area, it took longer and more resources to fix the proper area.
    • When data is purported to have “concluded” anything, first give it a reality check!
    • Data is only as good as the inputs.
    • Humans live in the real world, whereas data lives in an altered reality that mimics (rarely) the real world.
    • Never forget, data lies. Data can, at best, only support a decision direction.  Data cannot conclude, prove, or justify anything.
  6. The Rule of 6-P’s – The Rule of 6-P’s is known in various forms and words, but the sentiment is always the same, “Proper, Prior, Planning, Prevents, Purely, Poor, Performance.” Yet, how often is planning done without proper prior activities?  How often is poor performance blamed on everything but poor prior planning?
    • Do you know what proper prior planning looks like as an activity?
    • What is involved in prior planning, and how do you tell the difference between proper and improper prior planning?
    • Who is involved in prior planning and why are they there?
  7. Celebrate small achievements! – Here is another open secret, rarely implemented, always discounted, but remains the single most powerful tool in a leader’s toolbox, praise! That’s it.  Praise is better than cash gifts for the brain, research and fMRI imagery support this conclusion.  The research is fascinating.  Yet, honest, regular, sincere praise continues to be the most overlooked aspect of leadership in business today!
    • Praise is celebrating achievement with someone else.
    • Celebrating success is imperative to moral, discipline, and enthusiasm in the workplace.
    • When was the last time you showed genuine praise for your people? When was the last tangible “Thank you” witnessed?  Who witnessed that gratitude, praise, and celebration?
    • Mark Twain is quoted as saying, “I can live for two months on a good compliment.” Issue praise!  Celebrate all achievements, but most of all celebrate the small achievements.
  8. Success is a choice, but you need everyone making this choice! – Find me a successful team where one team member is not fully and wholly committed to achieving success, and I will show you a team that missed achieving the highest success. Production goals are the exact same thing, if everyone on the team does not know the goal, know the why, and are committed to achieving the production goal, that goal will be missed!
    • How do you find the person not interested in achieving the production goal; who is dropping trash and not picking it up?
    • What do you do when the person is identified; that depends, are you a learning organization or a money pit? If a money pit, that person is fired.  If a learning organization, then it is time to ask questions, discover reasons, and explore options.
    • How do you choose to lead, carrot or stick?
  9. Success is designed; who is drawing the lines? – One of the most egregious problems in today’s world is the delegation of authority to those not worthy or capable. On a consultation the boss had delegated his role to an author of a book.  Every question asked of the leader, he grabbed this author’s book and looked for an answer.  The book is a good resource, but the lack of application to direct business problems was not the author’s intent and was beyond the authors ability.
    • Who is drawing the lines designing what success looks like?
    • Why?
  10. The Pyramid Analogy – Use it, Live it, Love it!

The Pyramid Analogy

Consider the triangle from geometry, there are six different classifications, all of which demonstrate production goal attainment, but only the equilateral triangle makes up the pyramid, and only the equilateral triangle can report success in production goal attainment.

Right Triangles:

Right triangle - WikipediaA right triangle has one 90° angle.

The Acute:

Acute triangle | Acute angled triangle
The Acute Triangle has three acute angles (an acute angle measure less than 90°).

The Obtuse:

Obtuse Angled Triangle | Formula and Properties | Solved Examples & Practice Questions
The Obtuse Triangle has an obtuse angle (an obtuse angle is more than 90°).  Since the total degrees in any triangle is 180°, an obtuse triangle can only have one angle that measures more than 90°.

The Isosceles:

Properties of Isosceles Triangle - Definition & Solved Examples
The Isosceles triangle has two equal sides and two equal angles.

The Scalene:

Scalene Triangle (Definition, Area, Perimeter & Examples)
The Scalene Triangle has no congruent sides. In other words, each side must have a different length.

The Equilateral:

Properties of Equilateral Triangles | Brilliant Math & Science Wiki
The Equilateral triangle has three congruent sides and three congruent angles.  Each angle is 60°.

The Pyramid is an interesting shape, it is self-replicating from a single equilateral triangle.  The pyramid is a five-sided object that represents one of the strongest shapes in the galaxy, with integrity to flex without breaking and being destroyed.  Did you know that if you drew straight lines inside the equilateral triangle, and bent the triangle along those lines, a pyramid would take shape?

Volume of a Pyramid - Assignment PointConsider the production environment and the variables generally fall into three categories, inbound, or products needed to make something for a customer; outbound, the product shipped to a customer; quality, the need to ensure the product is acceptable for the customer.

Using a right triangle, if outbound is the 90-degree angle, your quality is way out of reach, and inbound inputs and outbound deliveries are not being properly reviewed by quality.  Thus, the production environment cannot function to its fullest potential, because all three, inbound, outbound, and quality, are not working equally together.

Bobblehead DollTake any other triangle and the story is exactly the same.  When the inbound and the outbound are not equally bound to quality, and quality is not equally bound to inbound and outbound, resources are not properly shared, time is wasted, and production goals will never be met!  Arrange the variables anyway you prefer, and if the pattern is not an equilateral pattern, there is a problem in the production environment and production goals will be missed, opportunities, lost, and money follows potential right out the door.

Follow the rules and watch production meet goals almost by magic.  Fail to follow the rules and production will continue to struggle.  Production goals are effort incarnate, humans pump efforts in, looking for results.  The goals are statistical symbols reporting success, failure, and percentages of improvement towards goals.  At then end of the day, the human element is the only variable worthy of consideration in meeting production goals, and quality is the badge of honor in human efforts.  Thus, quality is the tool that promotes production goal attainment.

© 2021 M. Dave Salisbury
All Rights Reserved
The images used herein were obtained in the public domain; this author holds no copyright to the images displayed.

When Fiction is Reality – The World Weeps!

Exclamation MarkI find a piece of fiction masquerading as science from today’s email, and I cannot help but ask myself, when did fiction become a reality?  How did Orwell’s 1984 escape the pages and become a reality?  Why did Animal House exit the big screen and become a way of life?  Mark Twain is one of the most often quoted authors, and I particularly like his comments on statistics which is pertinent to today’s discussion on fiction.

“There are lies, damned lies, and statistics.”

Consider something with me; even if you initially disagree, please humor me.  Statistics prove nothing; the best a statistical analysis can ever do is represent a bias towards a specific course of action.  That is it!  Mark Twain’s quote describes the persuasive power of numbers, particularly the use of statistics to bolster weak arguments. Mark Twain’s point is used to doubt statistics to prove an opponent’s point.  Inherent in every statistical analysis are the researcher’s biases, the desire of the researcher to attempt to verify something via numbers that are generally unable to be proved otherwise.Anton Ego

Except research proves nothing; even peer-reviewed research, the gold standard in research, can only point a person towards a potential solution and encourage a person towards a course of action.  The numbers prove nothing, ever!  Many people have become convinced that statistical data is comparable to “Holy Writ,” which is erroneous and dangerous.  Let me prove it to you, please.

Project Implicit

Project implicit was designed by Harvard University, is hosted on Harvard’s servers, and is all about individual bias.  Implicit bias in statistics is described as bias that occurs automatically and unintentionally, that nevertheless affects judgments, decisions, and behaviors.  Bog-standard bias is considered attitudes, behaviors, and actions that are prejudiced in favor or opposition to a person, group, or thing.  But, here is the clincher, bias is judged by others as a projection of themselves when they encounter other people, places, or things.

Broccoli PNGFor example, President Bush I, did not like broccoli.  A prejudice, possibly from childhood, he does not like this vegetable and handled the situation poorly at a state dinner in Japan.  Not liking broccoli is a bog-standard bias.  Other people, especially those enjoying broccoli, will view this event and shake their heads, possibly even ridiculing the president for his disinterest in broccoli.  Others who agree that broccoli is nasty will not have a problem with the presidential bias against broccoli as they exercise the same intolerance.  Thus, a bias is a behavior, an attitude, and supporting actions against something, someone, or someplace, even if that bias is understood or not.

Implicit bias takes normal bias one step further, according to psychiatrists and psychologists.  The extra step includes the inability to explain why a person does not like broccoli.  If there is no hidden reasoning from childhood, traumatic experiences, or irrational fears, then bog-standard bias is considered implicit bias, as judged by the person observing the behaviors.  Are the differences apparent; the reason I ask this is because of the problem in naming biases, the individual doing the observing and judging.Implicit Bias Test

In a branch of science called “Chaos Theory,” there is a hypothesis “that people affect their environments to their own desires.”  The premise was accidentally discovered when humans observed particles under close study and observed under remote means, and the particles acted differently.  The human influence upon particles was a giant leap forward in science, and nowhere is the power of researchers more fully understood than in human sciences (psychology, psychiatry, etc.).  The human brain is wired to connect socially, which is part of the problem when humans are studied under observation.  The innate desire to connect means that people will choose differently when under direct observation, when under remote observation, and when under no observation.

Hence bias is a judgment of another as witnessed through a lens of another person’s understanding, opinions, biases, and experiences.  Researcher bias is a fact inescapable and remains a topic of discussion in every research paper as a contributing factor to the results.  Why; because the researcher’s influenced the results, influenced the data, and influenced the process to achieve their own desires for an outcome. QED: Thoughts become things.Thoughts Become Things | the quotes

Returning to Project Implicit, ask yourself, why would you allow someone else to judge you?  Do you know them?  Do they know you?  Do you fully appreciate that the other person and yourself will influence the results?

Project implicit claims to measure, using mathematical formula the bias of another person, using time and word lists.  Using this formula (v1-v2=BIAS), Project Implicit proclaims they can help you recognize implicit bias on a range of topics from racism to gender roles and from veggies to pets, all because the mathematics claim they are conducting science.  Except, the implicit association is rigged to produce the desired results, as discussed above; hence, where is the veracity?The problems with implicit bias training | The Spectator | Truth Conquers All

GIGO

Garbage in equals garbage out (GIGO) is an axiom that initially began in computer programming and signified that when you dump a bunch of garbage into a system, the results are garbage.  The same is true for every single human endeavor; when you begin with garbage, the best you get for a result is more garbage.  Returning to implicit associations as an indicator of implicit biases, ask yourself, who selected the terms associated with the topic under study, the researcher or the researchee?

Of course, the researcher selected the terms, chose the topic, and tested how fast you can associate a word with the topic under study.  Then comparing the two results declares you have a bias.  Except, do you have a bias; I do not think so!  But, that’s my bias, for I choose to believe that you know how to choose and act in social environments to your potential and desired outcomes.[الإنحياز الضمني] مكتبات التصنيف الجاهزة في العقل البشري | محمد بن نخيلان الشمري

An Example

I was ordered to take an implicit association test to measure my emotional intelligence in a previous position.  The test used word associations on the topic of gender roles and leadership.  Believe it or not, I failed that association test; I do not place genders into any roles as traditional or limited to one gender or the other.  The best leaders are good followers; leaders are not born, they are made; gender, like race, never plays a role in the leadership potential of the person in charge.  Yet, when I failed the association test, my organization was informed I was obstinate, difficult, and opinionated; not that I deny these accusations, I simply refuse to fit into a pre-determined box.  Plus, I would see more people escape the box that has been built for them to “fit” into!https://c1.staticflickr.com/9/8368/8537356422_23bf051215_b.jpg

Later that same week, I snuck into the association exam a second and third time, mainly because the researchers kept sending active links that did not discriminate against logins that had previously taken their test.  Yes, I intentionally poked holes into these researcher’s pet project, and I will explain in a minute why.  On my second attempt, I chose what the results considered a “traditional male” with a bias against women.  In the third attempt, I decided to be a woman with a grudge against men and their traditional roles.  I wanted to show how irrelevant these word association tests are and how the results should never be taken seriously.

My plan backfired; my employer was not happy.  The researchers had to scrap their entire data set and go back to the drawing board to fix the research plan, and then after regaining approval, collect human testing data a second time.  Lots of prestige was lost for my employer.  I did not care then; I care less even now; even though I eventually left that position with people angry with me, I do not regret my actions.  Thankfully, I was not the only person offended by the word associations and the results which “snuck back” to play!Mediocrity Joke

Why is this important?

The answer to why these topics are important is found in the principles outlined:

  1. Statistics prove nothing!
  2. Statistics can only support a course of action!
  3. Research can only support a decision!
  4. Research cannot prove anything!
  5. Faux science abounds, and until researchers and academia acknowledge this problem, it will only grow.
  6. Never believe what you read, see, or hear!
  7. Faux science is being used to classify, separate, denigrate, and deride!
  8. Faux science is the excuse for stealing your liberty, freedoms, and legal rights under the US Constitution!
  9. Faux science crops up in courtrooms which is a cause for bad case law, which develops into detestable legislation!
  10. Faux science looks, sounds, and appears legitimate until you dig deeper. If you do not dig, you will be misled!

Bobblehead DollI cannot stress enough the need for every person to stop accepting the box others claim you must live in to “get along and get ahead.”  You are an individual with inalienable rights, a brilliant mind, and unlimited potential.  You are needed on the front lines of the battlefields of today.  You must play an active role, or you will not be able to leave the American Heritage and this great Republic to your children and community.

But, like the “Reading Rainbow” used to proclaim, “Don’t take my word for it!”  Meaning explore, doubt, ask questions, and keep asking questions until you are satisfied the answers are truthful, without dissemination.  Liars will tell you a thousand truths to get you to believe a single lie.  But, do not take my word for it; prove it to yourself; then teach it to another person so that you can learn more perfectly.Reading Rainbow

© 2021 M. Dave Salisbury
All Rights Reserved
The images used herein were obtained in the public domain; this author holds no copyright to the images displayed.