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Culture Change through Kaizen Events

By: Bill Lowstuter

 

LEAN is about change and you cannot force anyone to change.  I know because I tried to change people for almost thirty years, as a VP of Operations of 5 different companies. I was never successful in changing people.  People do not accept change for many reasons such as: "I have been successful, so I must be doing something right, and I don't want to risk it."  Another frequent reason is that: "Management won't let us change, I tried that once before and it didn't work.  I told management lots of my ideas years ago and they did nothing."  There is frequently a culture of maintaining the status quo, avoiding risk, just working around the problem and continuing to firefight rather than change the process.   People have to want to change themselves, as culture change happens- one individual at a time.  It is personal.

So how do we get people to embrace change? 

People accept change that they are a part of creating.  It requires a shift in the paradigm from "I've always done it that way," to creating a new process that will allow them to be more successful.   They need to implement solutions that they believe will work better and make it easier for them to do their jobs.   

New experiences are required to have new (better) outcomes.  Here is a simple model to describe the change process.  Change requires new Experiences, which leads to new Beliefs about how the work should be performed.  The new Beliefs will lead to new Behaviors.  The new Behaviors will create new Outcomes.  This will allow the people doing the work to be more successful. Work becomes easier, simpler, with less stress, and greater job satisfaction.

During a Kaizen Event, we have the people who do the work observe their peers, collect data and draw spaghetti diagrams to see first-hand the inefficiency and waste in their present work processes. This begins the task of getting people to think there may be an easier, better way.  During the week, the team develops new ways of thinking about the work and creates new processes.  These new processes are then tested and data is collected to provide the new Experiences and Beliefs that the changes will make jobs easier, rather than harder.   The participants begin to share their new Lean learning with their co-workers (new Behaviors) as they are now more open to change.  At the end of the week, they return to work with some new Behaviors which will lead to improved Outcomes. 

Ups and Downs 

However, change is not always easy and it does not come without hard work and a team effort.  During the week, there is often a roller coaster ride of emotions as the team goes through the development steps of: Forming, Storming, Norming and finally Performing.  The week starts with everyone dubious about the value of the Kaizen Event.  It can get more emotional from there as they wrestle with how these new concepts and tools will work in their areas.  As the week goes on, new Lean ideas are generated and become the TEAM'S ideas.  The new processes are proven by trialing the changes, observing the new way of doing things, and quantifying the savings.  This is the basis for the new Experiences required for change.  Shifting the team members' paradigms and replacing them with new ways of working takes time.   People think differently about their job and begin to have new Outcomes at the end of the five days. 

Building Lean Capability 

Kaizen Events are one of the many new experiences that are needed to begin and sustain a Lean Transformation.  The length of the events must be adequate to make real change and allow the participants time to absorb the new ways of thinking about and doing work.  These are some of the key reasons why Kaizen Events are 5 days in length.  Over time, as the new Lean knowledge and experience takes hold, they can be applied to smaller scope problems in 2, 3 or 4-day events.  The important thing to remember is that Kaizen Events are as much about building Lean Capability in your organizations as they about getting improved outcomes.

 
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About the Author:

Bill Lowstuter is a Sr. Consultant with The ACCESS Group (TAG) and it's affiliate company Healthcare Performance Partners (HPP).  He has worked with both industry and healthcare clients throughout the USA.  Bill has overseen the implementation of Lean within numerous facilities and industries, and has a Bachelor of Science degree in Engineering from the University of Illinois. He has also conducted numerous seminars and conferences in Kaizen principles and Lean.

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