Category: Leadership

  • Self-Accountability Part 5

    Self-Accountability Part 5

    Step Three: Develop good habits

    We will talk much more about this in the section on Self-Discipline, but good habits are building blocks that will get you to where your personal development plan, that we built in step one, is heading.

    The first thing to focus on when starting to develop good habits is to remove bad ones, and one of the worst habits is creating excuses.

    Excuses are like layers to an onion, once you peel one excuse back, you find a new bad habit every time you look closer.

    If you turn in a report at work that’s full of typos and has errors that should have been caught, the excuse is “I only had 3 hours to write the report.”

    If we peel that back, we see that you weren’t assigned the project at 1 pm, to present at 4 pm – you just failed to properly manage the much longer time you actually had for the project – and it’s very likely there was more than enough time.

    Now the question is “why is your time managed so poorly?”

    Are you staying up late watching TV, that leaves you scrambling the morning the report is due?

    Are you not serious about the job, leading to sloppy work?

    Are you blaming other people for your failures?

    Either way, the burden of responsibility is on you and as long as you fail to hold yourself accountable, these mistakes are going to keep piling up.

    You’ll continue to disappoint yourself, and you’ll continue failing to reach your goals in the personal development plan we outlined earlier in the chapter.

    The good news is that you can turn it all around. It’s not easy for some people to honestly reflect on the causes of their problems, but it’s the most important work that you can do.

    Now we’re self-aware of where we are, and now we’re holding ourselves accountable for how we got there. In the next chapter, we’ll discuss what comes after that.

  • Self-Accountability Part 4

    Self-Accountability Part 4

    Step Two: Be Honest With Yourself

    Self-accountability is meaningless without honesty. It can be difficult to be honest with yourself, because then you’re pulling away all the excuses and rationalization that stand between you and what you want, but it’s the only way forward.

    This is a two-part process, the first part of which is simply putting your ego aside and realize that you don’t know everything. No one does, and it might be a tough pill to swallow, but you aren’t the exception. Having the courage to admit that you don’t know everything opens the door to the second part of this process: asking for help.

    I can speak personally about this, having spent around twenty years in my career thinking I knew everything and struggling all along the way.

    – If you want to spend your career making every single mistake possible, at the end of your career you could be the wisest and most experienced person in your field. You also spent decades learning and likely re-learning the same mistakes over and over again.

    – If you’re able to have a little humility and ask for help from people who have been where you are, you’ll find your growth will explode. Instead of a decade struggling on XYZ, you can find a veteran who can cut literally years off of your learning curve with a few sentences.

    – The old phrase about touching a hot stove isn’t really how the world works. In reality, there’s about 90% of people who have touched the stove once, keep touching it and constantly wonder why their hands hurt so much. Then there’s 9% who touch it once, and realize “that was a terrible idea” and don’t touch it again.

    Finally, we have the 1% who see everyone else cursing at the stove, holding their hands and have the courage to ask someone if they should touch the stove while everyone else gets burned.

    When you compound all of the time that asking for help can get you, it’s almost unbelievable how much faster you can develop than your peers. There’s no reward for re-inventing the wheel, and the vast majority of problems you’ll face in your career are similar to problems other people have faced.

    The best thing about asking others for help is they’ve already done the work, burned their hands and as long as you ask politely, you get the answers to the test.

    Now that we’re taking the fast lane towards success, let’s talk about the final step in becoming more self-accountable.

    Continued…

  • Self-Accountability Part 3

    Self-Accountability Part 3

    A great tool to help diagnose where these problems come into play is using the four quadrants from Stephen Covey’s great book, “The Seven Habits of Highly Effective People” or sometimes called “The Eisenhower Matrix” after the famous General and President.

    Quad

    The quadrant is displayed at the left. Take any task that you need to perform and grade it on the two questions that follow.

    1. Is this urgent? – does this task require immediate attention or there will be negative consequences? Tasks that are urgent are like running water over a burned finger or paying rent on the first of the month. If you don’t handle them immediately, you’ll move significantly further from your goals.
    2. Is this task important? Will this specific task “move the needle” for whatever metrics you have designed in your personal development plan? This could be launching a marketing campaign for your business or applying to new jobs. The difficulty of a task can, but does not always, match the importance.

    The simple nature of the matrix is intuitive and easy to use, especially if you have experience running a team.

    The important and urgent (quadrant 1) is something you personally need to do immediately. This is the CEO returning the calls of the company’s attorneys: you don’t want the summer intern in charge of that, and you don’t wait until 3 months to call them back.

    The important but not urgent (quadrant 2) means you personally need to plan out where the process is going. When a home builder sells a home, one of the first steps is planning all of the components and craftsmen necessary to get the entire project done. If windows are on a 3 month lead time, not the usual 2 weeks, that’s not a problem the day the house is sold, but it’s an incredibly serious problem a month before turning the house over to the new owners. Taking that time to plan out what could turn from just important into important and urgent, and preventing those problems from happening is a huge return from a time perspective.

    Next is the urgent, but not important in quadrant 3. This could be something like “returning a current customer’s phone call about a non-critical issue”. If a customer wants clarification on a small item, it’s not something the CEO should focus on, but would be perfect for an hourly employee to do. The focus here is to delegate what is possible, to make sure you’re getting the best use of your time. Remember that as long as the task is done, you’re successful.

    Finally we have quadrant four, the least important and least urgent tasks. These are the easiest traps to fall into on your path to success, and eliminating these tasks completely is the goal.

    When entrepreneurs get started building their businesses, this is where so many get stuck in the mud: they want business cards, and logos, and talk about “what the company culture will be like”. Those tasks are great ways to avoid having to do the most important and urgent task entrepreneurs have: getting new, paying clients.

    – Jim Koch, the man who created the Boston Beer Company, best known for their Samuel Adams beer line, had a great story about when he was starting out. He had picked out the perfect logo, was looking at office space and had his eye on a massive computer system to handle processing all the orders he’d have.

    – The trouble was, he had zero orders. A family member who was an investor and had a background in finance finally sat him down and said “it doesn’t matter if you have the fanciest computer to process the orders, if you don’t have any orders to process.”

    – Jim was failing to properly categorize tasks using the quadrant above. He was luckily just wasted time, and not the precious start-up money, on the unimportant and not urgent tasks. After the conversation with the family member, he went into a bar with a six pack, sold his first few cases and now employs around 2000 people, generating over one billion dollars per year in revenue

    – Imagine what would have happened if he didn’t talk to the experienced family member? He could have spun his wheels for years, designing letterhead and who knows what other useless task, while the empire of Boston Beer Company faded away.

    The entire American craft brewing renaissance might not have happened if Jim didn’t have that one conversation – and more importantly – implement the action that was recommended.

    – How are you cutting yourself short in the impact that you’re able to make to the world? That’s what the quadrant is designed to improve, not just the insight, but how you can take the insights learned into action.

    – When you’re assessing your personal development plan, you can use this matrix on the front and back end, as both a planning tool and one for diagnosis of failure. If you’re finished with your whole plan, but before you implement it you do a quick check of all of the daily plans against this matrix, you can save yourself a ton of wasted time on the front end: could half of these tasks be delegated, and a quarter totally eliminated?

    – Next you can use it on the back end. Take time every three months, six months, whatever interval makes sense to do an audit of your activity. Were you actually delegating the urgent but not important? Did you spend two weeks building a social media presence for a business that isn’t necessary or likely to get new clients for your small consultancy? Did you prioritize your day to solve urgent and important problems, every single day?

    Use the feedback to change habits, not feel sorry for yourself, and your creativity at solving the problems will skyrocket, and so will your progress towards your goals.

    Once you’ve made the plan outlined above, you’re taking the daily action necessary to meet your specific goals that are all outlined and you’re taking a look at the plan every few months to make sure you’re not focused on unnecessary things, we can consider step one completed.

    The next thing we need to focus on is step two.

    Continued…

  • Self-Accountability Part 2

    Self-Accountability Part 2

    Step 1: Know your role and your responsibilities

    The first step in creating more self-accountability is to start by making an assessment of what your role is and what those specific responsibilities are.

    If you’re a father, your role and responsibilities are very different than if you’re the head of an emergency room, or if you’re coach of a basketball team. Every area of your life can have different roles, but the responsibilities of being a father, for example, can impact the responsibilities of being an entrepreneur. You will need to think about how late nights in the office can affect missing Timmy’s baseball game into your plan.

    No matter what your specific role is, you need to sit down and describe specifically what your responsibilities are. Without explicitly stating what your responsibilities are, you will never be able to hold yourself accountable.

    When you’re making this list of responsibilities, you’re going to break down each broad responsibility into the specific and measurable components that combine to form the responsibility. If the components are not specific, you won’t know that you’re working towards them, and if they’re not measurable, you won’t know if you’re succeeding or failing.

    Within each of these components that make up the responsibility, there’s going to be tactical strategies that will get you closer to the goal. These will be things that will be more day-to-day, so you can take down a larger goal one piece at a time.

    In practice, it could look like this:

    Role: A Father & Husband

    Responsibility 1) Make sure the family is financially stable

    Component A) Pay off wife’s student loan debt in 3 years

    1. Restructure current debt to reduce interest rate
    2. Add $50 more per payment to shorten duration to pay

    Component B) Increase income by $15,000 this year

    1. Pick up an extra shift every other weekend
    2. Earn a professional credential that raises your salary within the next six months

    III.          Help wife start tutoring local students

    Component C) Decrease spending by $1000 per month

    1. Pack lunch every day, saving $100/week
    2. Explore free hobbies that the kids enjoy

    Responsibility 2) Improve the family’s relationships

    Component A) Make routines more consistent

    1. Eat dinner together 5 nights a week

    Ii. Start a monthly tradition (family outing etc)

    Component B, C, D etc…

    You start by creating a list of just the responsibilities that the role requires: are you making sure that there are no injuries on the shift you supervise, reducing waste, mentoring junior employees, any imaginable amount of realistic responsibilities for whatever role you’re in.

    The four kinds of accountability mentioned at the beginning of the chapter should spark some creativity for responsibilities that might not be immediately obvious. The second shift supervisor is directly accountable to the Operations Manager he reports to, but he also has responsibilities to not setup the third shift supervisor for failure. If second shift is above quota every day, but third shift has started falling behind it means that somewhere, something is going wrong.

    Once you have the responsibilities, break them down into the components that would lead to success in that responsibility. Then break down each component into whatever metrics would be considered success in that component. This is where you’re going to focus your daily effort.

    Once you have broken down the strategic (higher level) into the tactical (day-to-day) steps necessary to move forward, now you have something that you can focus on every single day.

    Every day, you can look back and ask yourself if you were taking the steps necessary to get to the end position you want to be in, and this is what self-accountability is all about.

    This list of responsibilities is a document that should be referenced as often as necessary to get where you want to go. You should reassess the strategic level goals every three, six or twelve months to make sure that you’re still on the right general path.

    You should be checking weekly or every other week to see if you’re doing the tactical steps that will feed into the responsibilities success. If you spend two weeks without having done a single daily step, it’s critical to take a look at why you weren’t able to.

    This is where the self-accountability comes into play. If you are looking at getting back into shape as a goal, and you spend 2 weeks without exercising once, then there’s feedback that something needs to change. It’s important to note that this doesn’t mean that you’re instantly a failure and it’s time to give up all together.

    If your excuse was that you forgot your gym clothes at home, start putting a gym bag with two sets of clean work out clothes in the trunk of your car. If your gym is 30 minutes away, change your protocol to “if I don’t go to the gym on this day, I need to do 50 pushups before I can turn the TV on at home”.

    Continued…

  • Self-Accountability Part 1

    Self-Accountability Part 1

    In the last blog, we discussed why Self-Awareness is the starting point for any real change. If you aren’t able to honestly know where you are, you’ll never get on the proper path towards where you want to go. The next step in making forward progress is understanding how you got to where you are.

    This is where self-accountability comes into the conversation.

    Simply put, self-accountability is the understanding that you are the combined result of all of the decisions you make, and actions that you take.

    Throughout life, there’s roughly a 90/10 split on how much of life is based on your decisions, and 10% of what happens to you in life is just out of your control.

    For example, on the first day of your new job, you can go to sleep early, get your lunch prepared, have any paperwork needed for HR, time out your commute with plenty of slack in case traffic is worse, make sure you have a full gas tank so you make good time, but if you get in a car accident on the way, that’s just out of your control.

    The trouble most people have is that we spend the vast majority of our effort on the 10% that’s just beyond your control. People will blame circumstances, luck or whatever puts the burden of responsibility on anything but themselves.

    The reality is that the 90% portion is the only thing you have control over: if you can’t control it, it’s not worth worrying about, because you can’t control it.

    Once we’ve accepted the reality that the 10% is just out of our control, we get into self-accountability, and we’re able to start making serious progress on changing the path we’re on.

    As we move forward with accountability, it’s important to understand that there’s four general types of accountabilities.

    1. Individual Accountability: this is when one person is a part of the solution, for example, a coach who’s responsible for other people’s growth.
    2. Reciprocal Accountability: This is a group being individually responsible for a single goal, for example, the first, second and third shift managers of a single factory line. If second shift leaves a large mess, that can affect third shift’s productivity even though it might not be their fault.
    3. Team Accountability: This is how everyone on the sales team is responsible for hitting the quota, and the failure of the team as a whole is unacceptable, even if there are specific people who performed well enough.
    4. Self-Accountability: This means that you are responsible for your own choices and actions. You are the first and last line of defense for your own integrity.

    These four distinct areas of accountability can demonstrate the ways that you can have a single boss at your job, but that doesn’t mean you are only responsible to them. Salesmen might report into a sales manager, but if they can’t produce the revenue to cover payroll, the salesmen will find there’s quite a few people that rely on them!

    Every one of the components discussed in this blog can be difficult to implement, but self-accountability is the toughest for many people. It’s not a common trait to be able to look yourself in the mirror and not only know that you’re responsible for the vast majority of your problems, but that you’re the only one who has the power to fix them. The benefit to that skill is once you’re able to admit to yourself you can fix the problems, the solutions to those problems can start to show themselves, and they aren’t as big of problems to face as you originally thought.

    Now that we’ve outlined what self-accountability is we can talk more about what we can do to make ourselves more accountable. Luckily, we have a three-step plan to do just that!

    Continued…

  • Understanding Plant Losses

    Understanding Plant Losses

    The Way Losses are Calculated
    and OEE/TEEP Calculation

    In order to get a broad, clear picture of where to focus, you have to view your whole plant as a large system of fully manageable processes. No matter your role, your job is to improve plant processes, helping to produce the highest quality product, at the lowest price possible, in the safest manner. In order to see this big picture, you have to be honest and expose true problems within your facility. From that perspective, you will be able to recognize the different types of losses in your plant and how to secure significant gains in productivity by controlling those losses.

    How to determine where to focus

    The examples in this article use weekly numbers, but the same analysis can and should also be applied monthly, quarterly, and annually. Here we will look at how we apply metrics to some of the different loss types. Armed with an understanding of how your plant is losing productivity and how to measure those losses, you can effectively increase profitability. Let’s look at a few areas of loss.

    Available Time To Produce (Loading)
    1. First, you figure all scheduled downtime. Remember your buckets and put time scheduled in each of the buckets: Changeovers, Engineering Planned Shutdown, Maintenance Planned Shutdown, Operations Planned Shutdown, or No Customer Orders.
    2. Add them all together to come up with your Scheduled Downtime.
    3. Then subtract that from total hours in a week (168 hours available).

    Example: (Planned Maintenance of 24 hours) + (Changeovers of 4 hours) = 28 hours of scheduled downtime.
    (168 hours in a week) – (28 hours Scheduled Downtime) = 140 hours available to produce.

    Loading Calculation: (140 scheduled production hours) / (168 hours in a week) = 83%

    This gives you your Available Time To Produce, 140 hours per week or 83%.

    Quality Rate

    Start by taking your startup rejects and your in-process rejects, add them together, then subtract that value from your total units produced.

    Example: (35 Startup Rejects) + (35 In-Process Rejects) = 70 Rejects.
                   7,070 Total Units Produced.
    7,070 70 = 7,000 Good Units Produced.

    Quality Rate Calculation: (Good Units Produced) / (Total Units Produced) or 7,000 / 7,070 = 99%

    Net Good Processing Hours

    Find your Net Good Processing Hours by dividing your Average Weekly Throughput by your Weekly Design Rate.

    Example: Average Weekly Rate is 7,000 units produced.
    Weekly Design Rate is 100 units per hour.
    7,000 / 100 = 70 Net Good Processing Hours.

    Then, divide your Net Good Processing Hours by your Available Time To Produce.

    Example:  Available Time To Produce is 140 hours weekly.
    70 Net Good Processing Hours / 140 Available Hours To Produce = 50%

    Net Good Processing Hours Calculation: (Average Weekly Rate) / (Weekly Design Rate)
    That is, (Weekly Units Produced) / (Weekly Design Units per Hour)

    Availability

    Begin by taking your Average Breakdown Downtime, Process Failure Downtime and Set/Adjustment Downtime, adding them together, then subtracting the total from the Available Time To Produce.

    Example: (13 hours of Breakdowns) + (1 hour of Process Failures) + (1 hour of Setup/Adjustment) = 15 hours downtime
    (140 hours Available Time To Produce) (15 hours Downtime) = 125 hours Availability per week

    Availability Calculation: (125 hours Availability) / (140 hours Available Time To Produce) = 89% Availability

    Performance

    First, take your Actual Weekly Run Rate and subtract it from the Weekly Design Rate.

    Example: (Weekly Design Rate of 100 per hour) (Actual Weekly Run Rate of 85 per hour) = 15 units per hour lost.

    To convert that loss to hours, divide the Actual Weekly Run Rate by the Weekly Design Rate, subtract that quotient from 100, then multiply that difference by the Availability (in hours per week).

    Example: ( 100 (Actual Weekly Run Rate) / (Weekly Design Rate) ) x (Weekly Availability)
    ( 100 (85 units/hr / 100 units/hr) ) x (125 hours available to produce) = 19 hours in speed losses

    Now, subtract the hours in Speed Losses from the Weekly Availability hours to get Available Time To Produce.

    Example: (125 hours Weekly Availability) (19 hours in Speed Losses) = 106 hours Available Time To Produce.

    To find minor stops, subtract your Net Good Processing Hours from your Available Time To Produce.

    Example: (106 hours Available Time To Produce) (70 hours Net Good Processing Hours) = 36 hours of minor stops per week.

    Performance Calculation: (Speed Losses + Minor Stops) / Weekly Availability
    (19 hours in Speed Losses + 36 hours in Minor Stops) / (125 hours Weekly Availabilty)
    (19 + 36) / 125 = 56% Performance

    OEE/TEEP Calculations: OEE = Availability * Performance * Quality
    OEE = 89% * 56% * 99% = 49%
    TEEP = Loading * OEE     (Loading = Percentage Available Time To Produce)
    TEEP = 83% * 49% = 41%

    7 Big Losses: Minor Stops: 36 hours per week
    Speed Losses: 19 hours per week
    Breakdowns: 14 hours per week
    Process Failures: 1 hour per week
    Setup/Adjustment Losses: 1 hour per week
    Quality Startup Losses: 0.5 hour per week
    Quality In-Process Losses: 0.5 hour per week

    If these were your numbers, where would you focus?

  • Why Do We Not Want Help?

    Why Do We Not Want Help?

    In many dealings throughout my career, including myself, it seems common place that people do not want to admit the need for help. From physically, mentally, in life, or in business, our ego’s seem to always keep us from reaching our full potential.

    As It Relates to Business

    When it comes to business world, why do we allow ego to kill our businesses? Truly successful people understand their need for help. They understand what their gaps are and the need to use others to close them. Outside help is the help that is normally needed. If the organization had the internal knowledge and skills, they would have driven the needed improvements. The exception is if you have superstars that you know are some of the best in the industry working for you already, but you have pushed them to the side, maybe you need to unleash them on the organization. In my opinion, there are three main reasons as to why people do not ask for help and/or any combination of the three.

    Ego

    9 times out of 10 the cause of ego is due to a lack of knowledge. People with ego believe that they know more than they actually do, which creates an overconfidence in their abilities. Einstein’s Theory of Knowledge states that Ego = 1/knowledge. In other words, the more knowledge you have, the more you realize you do not know, thus, less ego.

    Fear

    Fear normally ties to ego. It is the fear of looking incompetent due to the lack of knowledge which would drive the need for help but is refused. People fear looking like they cannot do a certain task or job. It makes them fell inferior and that is not a feeling that people like to experience. Great leaders understand that they need the help, which is why they are successful.

    Cost

    To understand the cost of help, most people look at this backwards. They look at bringing in help as an expense, not an investment. For example, if I were contracted to do work for $100k, people look at the $100k and say that it is expensive. What if you looked at it as an investment, understand that you will provide a return much greater to the organization. If I were to help you resolve issues that are troubling your organization, it is possible to get a 10 to 50 time’s investment or even more! The best of all is the fact that you are now the hero.

    My Growth

    My growth took off exponentially when I realized I did not know everything and I reached out for help. I spent many years thinking that I was the best, and I was, at managing the reactive state of maintenance. I had no concept of proactive maintenance. I just knew that my job was to keep the plant running, and I did just that. Working 20 hour days was my responsibility.

    The Defining Moment

    One day, as we were working on the implementation of a CMMS system, I met a gentlemen that told me everything that I was doing was of truly no benefit. He sat me down and walked through some of the things I should have been doing and what I should not have been doing. He told me what I needed to hear, not what I wanted to hear. In my current state of immaturity, it made me mad, but I also new that he was only trying to help me. I told him I wanted to be the best, so if he could help me than I am all ears. He did just that. He loaded me down with books, answered my questions, and taught me things that I had no clue about. It began to open my eyes of this larger world that exists, and that is when I realized that I did not know anything, compared to what I thought I knew. From that point forward I began hiring anyone from the outside that I could to help me overcome my gaps, my weaknesses and help develop my strengths.

    Question

    What are some reasons as to why we think we do not need help?

  • Why the Maintenance Deficiency?

    Why the Maintenance Deficiency?

    The awareness gap results from management having limited or no knowledge of the maintenance function and its ability to contribute to the manufacturing process; and maintenance personnel, managers included, having limited understanding of the business side of manufacturing. The result is that management and maintenance are often unsure how they together contribute to the company’s success.

    Your Company’s Maintenance Attitude

    When I ask managers or hourly workers what their organization’s perception of maintenance is, I tend to get the same types of responses. I hear things like:

    • Maintenance is a cost center
    • Maintenance is a necessary evil
    • Maintenance is the cost of doing business
    • Maintenance personnel are firefighters

    When asked to define maintenance, they offer words such as fix, restore, replace, recondition, patch and rebuild. I’d say these are reactive definitions of the word. What is maintenance? Maintenance is to maintain or the act of maintaining. The basis for maintaining is to keep something in a specific state or condition – that is, to keep it (the asset, in our case) in an existing state or preserve it from failure or decline. There is a world of difference between this definition and the words and functions normally recalled by most people who are “knowledgeable” about the maintenance function. The best way to change the perspective is to show the entire organization how it is that maintenance provides value. To keep things simple here, let’s focus on three types of value: convenience, process improvement, and financial value.

    • Convenience is sold through a demonstrated or statistical approach to prove that a plant will be safer and will produce higher-quality product, resulting in less rework. Greater production efficiency means lower costs; lower costs gives us marketing advantage; marketing advantage and enhanced competitiveness can promote job security. You empower people to do what they know to do by providing the proper tools and removing obstacles to their getting it done.
    • Process improvement is sold through less downtime. This means running to plan, which makes the production manager look like a superhero. Better asset use improves capacity, which means more volume, more profit, and more recognition. Also, less downtime results in less frustration, raising morale and helping to drive culture change.
    • Financial value is sold through the freeing of cash flow, reduced costs, and higher profits. These all translate into two things: higher stock value and more capital for reinvestment into the company.