From: Norman Bodek
Sent: February 25, 2005
I did receive some very nice emails encouraging me to continue sharing the eight
conditions for flow production from Mr. Hiroyuko Hirano.
Condition 1: "To lay out facilities in the sequence
Condition 2: "To make
facilities small and exclusive use."
Many years back in Japan I spent several days with Mr. Chihiro Nakao visiting some of his
clients. Earlier he had spent many years at a Toyota subsidiary working with Mr.
Ohno and Dr. Shingo converting Toyota suppliers to just-in-time. One day he said,
Norman, a machine should be only four times larger than the part. A very
simple statement that was also very powerful. It was something that I had never
thought about before. We get locked into paradigms that machines should cost a lot of
money, be big, heavy, made of steel, unmovable bolted to the floor, dirty,
dripping oil, outer black panels covering the machines insides, repaired only by
maintenance engineers, very long set-up times required, etc. Now with a very simple
statement all of the past perceptions were blown away.
Look, with small machines we can easily move them into one-piece flow cells, make repairs
quickly, teach operators how to fix the machines, eliminate the oil problems, etc.
In the past, we thought that machines should have many bells and whistles, with
features to use just-in-case. Now we know that we want simple
inexpensive machines that can be used for one purpose, to produce what is required by the
customer to make the product, easily worked on by the workers or robots, installed with
very simple grasping and release features to allow people to be separated from the
machines, etc. You change a whole paradigm when you say, the machine should be
only four times the size of the part.
First reaction, either crazy, or cant be done, but after you get
over the initial shock, you can sit down and try to figure out a way for it to happen.
I remember earlier in my life when I was president of a Data Processing company with a
facility in Grenada in the Caribbean. I was given a very large and very difficult
conversion project from the New York Telephone. It took me months to really
understand the customers requirements and now I stood in front of 150 data entry
operators in Grenada, many of them with only an eighth grade education, and I had to
somehow teach them how to do this very complicated job. At first, I thought it
couldnt be done. Then I thought. I had no choice. If I wanted to
continue eating they had to do it and they had to do it successfully. Once I broke through
the greatest barrier, my own mind, slowly these wonderful people fully grasped
the work and succeeded splendidly.
I realized then that the biggest barrier to change was me. Once you can realize that
you can do almost anything. So work with this second condition and see how it
applies to you and let me hear from you.
You might like to read my book Kaikaku The Power and Magic of Lean and also Chuck Yorke
and I just finished our new book All You Gotta Do Is Ask.