In Their Own Words

In our 30th "Deming Lens" episode, host Tripp Babbitt shares his interpretation of wide-ranging aspects and implications of Dr. Deming's theory of management. This week he looks at the problems with goals, targets and quotas.

[00:00:14]
Deming Lens - Episode 30

[00:00:32]
The Problems with Goals, Targets and Quotas

[00:06:35]
System Capability

[00:09:28]
Arbitrary vs. Rational Goals, Targets and Quotas

[00:12:48]
Financial Targets

Tripp: [00:00:14] In episode 30 of the Deming lens, we'll take a look at the problems with goals, targets and quotas, including looking at system capability, arbitrary versus rational goals and financial targets.

Tripp: [00:00:32] Hi, I'm Tripp Babbitt, host of the Deming Lens, and this week I'm going to cover the problems with goals, targets and quotas. Now this goes back to my series that I just completed on Demings, Dr. Demings 14 points, which is point eleven, eliminate numerical goals, numerical quotas and embryo substitute leadership. And the reason I'm bringing it back up is because it's been very well publicized lately with a lot of things that are going on, especially around this time of the year with the delivering of packages and things of this sort. But I want to start with a story that I experienced when I was back in college. And a friend of mine came to me and said, hey, guy found a great summer job. We can go and work at RCA. Now, RCA was unionized and he knew somebody in the union and they were looking for extra workers for the summer. And this particular plant that we were gonna be workers at for RCA did vinyl records. And so are we. We signed up. We were paid a lot more than I would have made anywhere else because of the union types of salaries, which was an interesting experience in itself. Not for this. This podcast episode, though. So we went in, we were trained, but the job was fundamentally what I would have called easy to do. And basically what you did is you had a.

Tripp: [00:02:28] Next to a pile of vinyl stock, and you would take this vinyl stock and you would place it on this machine and your hands would go up and grab a couple handles and you would pull the press down on top of the vinyl stock and it would create a record. And that was the job in essence.

Tripp: [00:02:53] And obviously, you would lift it back up. You take the record out, you put it in place and you go on to the next one. Well, I had a quote. I don't remember what the quota was. This is quite a while ago, probably 40 years ago or more. And I remember doing it and I was putting it out. I knew I was working faster than everybody else because I could just see the volume of things that I was doing. And, you know, it wasn't anything I really had to do because once I put the press down, it was timed. So it would automatically go and press the record. Well, I did this for the first couple of days and I came and got paid attention to by management.

Tripp: [00:03:37] And they said, you are creating a lot of rework. You have defects in your vinyl records, and I was like, okay, I'll try and do better.

Tripp: [00:03:55] I didn't really know what to do better. So I went and I continued to do really what I was already doing. I was trying to pay attention, okay, what did I miss? Something. I watched other people. Is there something in them that I wasn't doing that they were doing? And I went through this process and. Lo and behold, they come back to me a couple of days later and they say, hey, your error rate is still twice as high as everyone else's. And I said, hey, look, you know, watch me do the job. And so they watched. And, you know, basically they had no clue it was that I was doing. So I continued to do it and they finally came back to me. After going back and forth, both basically time me, my error rate was still twice as high. I even slowed down. I mean, I thought, well, maybe I'm getting paid attention because I'm in the union. I'm going too fast or something to that effect. But they just basically said, no, you're your area rates twice as high as everyone else. We're sorry. We're gonna to let you go. So I was let go at that point. I was puzzled. I was it was kind of a demeaning experience. And what I found out later from my friend who had continued to work there was the machine that they had put me on, was responsible for a high error rate in the union, knew this, but they were never able to get it fixed to management.

Tripp: [00:05:26] I don't know whether it was a matter of funds or, you know, you could speculate as to what was going on. And so whoever wound up on that machine would have a higher error rate. Well, it sounds ridiculous, but this is kind of the whole thing around code is it's it wasn't a matter of I could certainly put out the volume, but the defects were there because the machine was broken. And, you know, you see a lot of this today. And so when we're looking at quotas and targets and goals and things of that sort. You know, I first think in terms of several things.

Tripp: [00:06:10] One is we'll cover each one of these is the what is the system system capable of doing? Talk a little bit about arbitrary versus rational goals, targets and quotas. And then the third thing I would talk about is the financial defense. Financial targets are outcomes and we use these as goals and things of that sort.

Tripp: [00:06:35] So let's start with the first one, which is system capability. And we looked at the machine that I was working on and it was capable spitting out quite a few, but it was also vinyl records, but it was also capable of creating high defects.

Tripp: [00:06:50] Now, any today I would have gone with that machine and I would have known what the defect rate was had been able to compare. I would have known not to blame the worker, but the main thing was the system. In this case, the machine and myself were not capable of meeting this quota of the number of things because of the high number of defects that I was producing. And so, you know, we see this and this is why I'm doing this particular Deming lenses in this episode is because right now we're in the Christmas season and people are buying gifts and a lot of them are being bought online. You hear these horror stories, not only of porch pirates, but you also hear about people throwing packages. You hear about wrecks that are happening because they're trying to work at breakneck speeds in order to deliver these packages. And so this is kind of the clue of system capability, even hiring more workers. Did they get trained? Who knows? But in essence, the system, the wheels begin to fall off in your in your organization when it's operating beyond its capability.

Tripp: [00:08:14] Now, it might work. Okay. In the short term. So in other words, I could work, you know, 100 hour weeks for maybe a couple weeks before I start to wear out as a human.

Tripp: [00:08:27] And but but working at some of these speeds, you start to see the people throw the packages onto the porch. You see them operate just to be able to meet whatever quota is that they're trained to to do. And this goes for pickers. This goes for fix repair. This goes for every type of industry, really, that I could think of as when a system is working beyond its capability, that that you start to see defects of some sort. And in this case, it might be, like I said, accidents, throwing packages and things of that sort. And bigger incentives to make these things happen, to meet these unrealistic quotas actually make the system. Worse. So the question becomes, how do we need to work on the system and we'll get back to this when we start talking about financial targets and third segment. Well. That's all I really have to say about that.

Tripp: [00:09:28] Now, the second part I want to cover is the arbitrary, the arbitrary versus rational goals, targets and quotas and rash. By rational, I mean that they are things that are tied to a rational goal would be, hey, if we don't get our defects down to 1 percent, we're gonna go out of business. That's that's a rational thing if it's true. You know, we can't compete if we're at 5 percent and everybody else is at 2 percent or 1 percent.

Tripp: [00:10:01] So we have to have certain goals, targets or quotas based upon keeping, you know, staying in business. So what's differentiate between an arbitrary versus a rational goal, target or quota? So arbitrary just means I come up with a number. It's it's what you see a lot of times in strategic planning processes. Oh, next year we're going to grow by 15 percent and off everybody goes. And they tried to meet this arbitrary goal. And oftentimes these things are tied to things like management by objectives. We still see that. I still see it. It's unbelievable. I still see management by objectives in every company. And it's this very Taylor istick. This is Frederick Taylor back in the early nineteen hundreds where, you know, you're given your target and your goal, your objective. And you go out and you meet it and you get typically it's tied to some reward and that that too is tied to Frederick Taylor scientific management. The MBO concept itself came from Peter Drucker and actually when Deming Dr. Deming started railing against it. It was Dr. Drucker that came back and said, basically, that isn't the way I intended for management by objectives the work, but the whole concept regardless. The whole concept is based off of I have objectives. We break down though, the whole pieces. So in other words, if I'm going to go 15 percent increase in sales, what's your responsibility for the Northeast sales region and what is your responsibility for the western region and so forth? And so they're given these arbitrary goals based on it.

Tripp: [00:12:02] And if everybody meets their goal, supposedly everything gets better. Well, oftentimes you find the system that you work in is not the sum of its parts. It it's beyond. That's exponential. What you get the synergistic effect of being able to operate within a system is missing. And so we try to add up these parts, we break them or in this case, we're taking the 15 percent goal in sales and breaking it out by region. OK. You're going to do 10 percent. You're going to do 20 percent, because that's what we believe. These are arbitrary numbers. What we don't know is what the system's capable of. And this kind of leads us really all I have to say about that.

Tripp: [00:12:48] But is the financial targets that are associated with this. So the financial targets typically are, ah, arbitrary. But they're also outcomes, their outcomes of what we create. So it's a scorecard. And, you know, I, of course, hear about the balance scorecard and all those types of things balancing these things. It's to me, it doesn't make a lot of sense. But from a financial target standpoint being an outcome, the question becomes and it's Dr. Demings famous question, that is my favorite phrase, which is by what method? How are you going to achieve these financial targets? How are you going about getting a 15 percent increase in sales? How are you going to have less defects out of a particular manufacturing operation? And these are the things that are missed in when we're looking at numerical goals, quotas and things like weight management by objectives. So I'm hoping that by virtue of you listening, they should go and take a look at your world own organization. Look take a look at some of the goals that you set out. Are they tailoring stickin in nature? Have you taken a piece and then broken it out and then said, Oh, if everybody hits this now, you can go back and listen to Paul Marshall O'Bama companies. We talked about this to suit to a certain extent, which in the context of performance appraisals. But if everybody's hitting their performance appraisal numbers and the company is still going out of business, there is a problem. It's it's the system that needs to be work on. That needs to be improved. And we start to start asking the questions if we've got targets out there, whether they're financial or whatever, are they arbitrary? Are they rational tart targets? You know, and arbitrary. Still, somebody else is going to say, because I get this all the time when I'm talking to companies, there's always somebody in the organization.

Tripp: [00:15:03] I'll say, well, you know, Mike's not arbitrary because it was given to me by my manager. Well, that isn't what I mean. It's arbitrary by nature of the number itself. And do do you have a method to achieve it that you believe will work? And I think this is where people really miss out, is being able to find methods that will achieve the types of things, the types of increases that they're looking for. And it might be an innovation. It might be through failures, which is part of innovation. And you listen to the Doug Hall episodes where we talk about this to great extent about failing in order to get better and finding better methods. And really, the companies with the best methods are the ones that are going to be who wins the competitive battle that is out there between organizations. So so go out. Take a look at your goals, your numerical quotas, take a look at the embryo system if you have it. And I guess a lot of large companies have it. Amazing. But anyway, ask the question, do we have a method to achieve this? And if we don't, maybe we should be looking like looking at that as an organization.

Tripp: [00:16:28] Thank you for listening to the Deming Institute podcast. Stay updated on the latest blogs, podcasts, programs and other activities at Deming dot org.

In our 6th Interview episode, Plant Manager Dan Vermeesch and Quality Manager Brain Hoff discuss their Deming Journey. Topics include a discussion on variation and getting the Deming Philosophy into the education.

[00:00:12] Deming Institute Podcast Interview

[00:00:35] Micron Manufacturing

[00:00:50] History of Micron Manufacturing

[00:01:10] Dan Vermeesch

[00:01:51] Brian Hoff

[00:04:35] Dr. Deming at Micron

[00:05:18] Variation

[00:07:07] Eliminating Performance Reviews at Micron

[00:11:07] Struggles of Working with the Deming Philosophy

[00:14:39] Micron Gives Advice on Adopting the Deming Philosophy

[00:23:46] Shingo Silver Medallion

[00:24:39] Variation a Key to Micron Improvement

[00:31:33] Deming Needed in Education

Tripp: [00:00:12] In this Deming Institute interview, I speak with Dan Vermeesch and Brian Hoff of Μ Manufacturing in Grand Rapids, Michigan. We discuss the history of Μicron, their improvement journey and how the Dunning philosophy is affecting this journey today.

Tripp: [00:00:35] Hi, I'm Tripp Babbitt, host of the Deming Institute podcast. Our guests today are a couple of gentlemen from Micron Manufacturing, Dan Veermsch and Bryan Hoff. Welcome, gentlemen.

Dan: [00:00:48] Hi, Tripp. Thanks for having us.

Tripp: [00:00:50] Very good. So first of all, micro manufacturing I'm not familiar with it. Won't want to share a little bit about what Micron Manufacturing does and a little bit about both your gentlemans role in Micron churn, Micron manufacturing as it was using machine products company in Grand Rapids, Michigan.

Dan: [00:01:10] It's been in business since 1952, Ed and Jackie Preston founded it back then and until just a few months ago, Jackie Preston still came in every day, five days a week. She just turned ninety one a couple of weeks ago and she hasn't been in in a few months. But she was here every day until then. And it was great because her son currently is the president at Micron. And we have a niece and nephew that work here. And the nephew has a 5 year old daughter that comes in on Saturday and plays on a computer. So one of the best parts of the story of Micron is we have four generations in this building every week.

Dan: [00:01:51] And it really is part of the story that's important because there's a lot of family focus here at Micron that that's important to us. So I am the plant manager, have been the plant managers since 97 and also the lean champion that has tried to be the architect of some of the various improvements systems that we have had since the year 2000 is when we really begin implementing our transformational change. So I'll let Brian introduce you.

Tripp: [00:02:26] Okay.

Brian: [00:02:27] I'm Brian Hoff. I'm a quality manager at Micron. This would be my twenty second year with Micron. And as Dan said, it's around 2001. We began to be to transform our journey from kind of an old school business model to trying to adapt what is the best way to make change and improvement. And it's been an amazing journey. And lately we seem to have encountered Mr. Deming once again. And I guess I'm mature enough to understand it better than I did 20 years ago. And I'm using him almost daily to try to influence the decisions I make each day.

Tripp: [00:03:13] Very good. And where are you guys located?

Dan: [00:03:17] Grand Rapids, Michigan. OK. We're on a dead end street in the northwest corner of Grand Rapids, Michigan. So that's that's always part of my favorite part of the story here is we're kind of located on the edge to nothing. And despite all that, our folks here have made so many great changes over the years that we've had thousands of people from, I think, 26 states and eight countries that have come to visit us to see the systems that have been put into place over the years. And we're only a 40 person company. Twenty eight thousand square feet. So we're just a small about on the map that that over the years have made a big ripple in the pond. The precision machining industry. And it is exciting that we've got such a great group of folks that have not only made change, but we've made a lot of improvements over the years. But part of our story that we'll get into and will allow is we're making a lot of change, but we kind of lost sight of whether or not some of that was improvement. So we could see a lot of change around here. But the dials stopped moving after awhile. And so we had to go back to the drawing board. And that drawing board was Dr. Demings work.

Dan: [00:04:35] Okay, very good. Well, let's pick it up from there. So how did you guys come across Dr. Demings work? It sounds like maybe you initially knew Dr. Deming then kind of got away from it. So once you share a little bit about your journey there.

Brian: [00:04:52] So this, Brian, and back when I was a young 20 some year old, I happened to go to a statistics course, and during that course the instructor had mentioned Juran and Deming. So I began with Juran and in Juran Zone books, he mentioned Dr. Deming, so once I completed listening to the doctor, Mr. Grant, I read out of the crisis and.

Brian: [00:05:18] I don't know that it made complete sense to me at the time, but it did. The thing that got me was the study of variation. But so I spent five or six years diving kind of deep into statistics and I made some headway that wasn't I wasn't at Micron at that time. I was I was in the plastics industry. So when I joined my Mike Brown back in ninety one and.

Brian: [00:05:46] We were able to use some of the statistical tools so that in a way I was holding on to some old blood. Dr. Deming talked about variation. But I wasn't I wasn't truly knowledgeable about profound knowledge and the way to think of all of that. And then I admit to somehow I lost track of Dr. Deming for a decade or more. And then later, when Μicron started doing its deep transformation, Dr. Deming started coming to my mind more often. So I re-read the books again. And since then, it seems as though. There was a trajectory of adopting a little more of Dr. Deming, and then recently we seem to have found a new gear in regards to appreciating what he said.

Dan: [00:06:41] So a number of years ago, maybe the early 2000s. Brian and I have had a lot of conversations over our years of transformation. We always called it our lean journey. And that's that's how we knew it. But he would bring up regularly his views on variation. And then I asked, would you come up with all this? And we mentioned Dr. Deming and I need to learn more about this.

Dan: [00:07:07] Never, never really put forth the effort to do so. Until I was at a conference in Columbus, Ohio, I think about eight or nine years ago, and the speaker talked about the 14 points. It seems like I've heard of those in the past. Any you talk further about the doing performance evaluations and the disrespect that came from it. It just so happened to be the high end and pushing performance reviews here created a very in depth system. We're doing them quarterly. We're doing all this stuff and I hated every minute of it. And I couldn't put my finger on what was it that I felt that was wrong with it until I heard the speaker say just how disrespectful Dr. Deming felt that they were and why that day.

Dan: [00:07:58] I decided before I left that meeting, we were never doing another one. And I came back and I told our management team it's called team strategy. I apologize for pushing it so hard for so many years and shoved it down everybody's throat. And today we stop. I. I wish I would have gotten a picture of the room on that day, because I think the shock phase, after pushing it so hard that doing a complete 180, but it truly was like like seeing the sun come up because it put words to the feeling that was growing in me, that this is just wrong because half the people were walking out of the room feeling they were below average. Right. Who do you want to feel that way? And that was the day that I thought, I need to learn more about this guy.

Tripp: [00:08:46] Very interesting. So. So, yeah, go ahead.

Dan: [00:08:50] Oh, I'm sorry. So I was a few years after that that I don't and I can't recall right now how I caught wind of the Deming research conference in Fordham University in New York. And we've done a lot of presentations, like I mentioned earlier, sharing our lead story. And so I thought I'll submit and see us there is interested in her interest in hearing our story at the research conference. And then I was honored to be selected to do that. And.

Dan: [00:09:23] It was then that I met Dr. Demings, daughter and grandson, great grandson, and and heard everybody else that was speaking there, it truly became inspired by what I heard. And and Brian joined me on that trip and I brought my 15 year old daughter at the time and I thought because the story was about this whole story of Μicron. And I just wanted. I thought she needs to hear what grandpa and grandma created because I didn't mention earlier, I'm the son in law of the founders, but so I brought her with me.

Dan: [00:09:58] And it turns out she was the youngest attendee at a DME conference, I think, in the history of the den. And so Kevin and his wife is her name's Judy, I think, right? Yep. Yep. So they embraced her so much. I was really touched by that. So when the conference came to Michigan State University, where my daughter attends now at the conference, we walked in and she was just going to visit and say hi and whatever. And they made her so welcome. And got her a badge and invited her to attend a conference and everything. And it was really touching that they had a remembered her and they have really embraced a young person. And she's brought it up so many times. And and it's just that to me, that whole story just adds flavor to what I believe is the Deming community that I'm beginning to learn more about. So it's not just about the things he taught, but it's I'm beginning to see that the people that truly understand them are beginning to it. It's a group that we need to hang out with more. Right.

Tripp: [00:11:06] Very good..

Tripp: [00:11:07] So so let me ask you guys, when you started in to the Deming philosophy or as you've worked with with it, what things have you either personally struggle with or maybe even the organization has struggled with?

Dan: [00:11:23] So for me, I mentioned it again today in our strategy meeting to Brian and others that my 2019 transformation that came earlier this year when Dennis Sergent was the instructor of our Deming CQ Academy is what he calls it. And there was so much reference to improve it. So I love the statement. All premier requires change. Not all change results in improvement. So that was great to hear her have heard that before. But. I am a numbers guy. True and true on the facts and figures and dates and deadlines, you gotta go. You know, maybe that's part of being a plant manager. I don't know, but I begin to understand that.

Dan: [00:12:18] And then we've done a great job recently with our team strategy meetings. We are going to take a step in the right direction every day. And we we don't hold our feet to the fire like we used to about by this date. This thing has, you know, those kinds of things that the made up numbers of.

Dan: [00:12:35] You got to hit this goal by this day. We still have some of that. But there's far less focus on that than there was coming into 2019. And I struggle with it every day, every day that I bite my tongue and say, don't kick a no, don't create a no, don't push a number. Push the improvement and true change towards what we are looking to accomplish.

Dan: [00:13:01] And it's it's liberating, to say the very least. And again, it's humbling. It's almost like that day came back and say and said, when I do another performance evaluations offered me by longshot that because it's such a one idea who I am.

Tripp: [00:13:18] Interesting. Brian. Brian, how about you?

Brian: [00:13:22] Well, first, I want to attest to watching Dan's struggle with Martin.

Tripp: [00:13:28] Okay, so you've witnessed it. Okay, I got it. I think me.

Brian: [00:13:36] Oh, recently I encountered a. A customer had a problem, and normally if if we have material here that we asked to re-inspect, we learn how to do it. And we show another person how. And we call that a training system.

Brian: [00:13:53] And for some reason, and this particular incident, I decided instead of training the way I always have, I'm going to do it different. Because Mr. Deming said you should look harder at your training systems. There are likely problems there. And so I decided what would be a better way. And when I was done, it literally opened my mind to the amount of variation in a training system.

Brian: [00:14:22] Either doesn't pay attention to or creates all by itself, and so that would be a thing that recently happened to me in regards to understanding better, something that Mr. Deming talked about.

Tripp: [00:14:39] Very good. So here's a question for both of you. And it does matter what order that you respond. But if you were if you're a manufacturer, it's, say, listening to this podcast episode and you were thinking about this. What are some of the maybe, I don't know, pointers that you might give them about going to this philosophy, Will? What are the steps that you think they might go through or what advice might you have?

Dan: [00:15:10] That's a very good question. I think that as in most things, learning has to take place. And for me and for Brian, that fact he's got out of the crisis in his hands now, I've got some sticky notes in it.

Dan: [00:15:25] I get it. I always give Ryan a little ribbing because I call his Brian Dowling Bible here because he carries with him everywhere. I don't think I'd recognize him if he came to work about the thing in his hands. I think you have to start there. And I didn't start there. I just read the New Economics. In fact, I just got done with it in recent ago. First book I ever read.

Dan: [00:15:52] And then I have a long time ago, before I went to the Research Council that I read online, I learned more. I loved the history. I loved the fact that he grew up in a farming area and studied. How should it be? Because I grew up on of farm in Michigan here. So that really all resonated with me. And as I began to learn his story and his half life begins to patch together a lot of thoughts about how this may have all developed for him. And I want the history part of it. That's great. So I would suggest people be read about him and listen to these podcasts for sure.

Dan: [00:16:33] Look online if the educational beginning. But it was instrumental earlier this year. After all this time, haven't taken the Dennis Surgeons CGI Academy that really gave us this. It's what we did, guys. And I have to believe these types of sessions are all over the United States for people to be able to learn more and participate in groups. Exactly. And implement exactly what he's what he's trying to implement. And so through that, one of the things that's occurred to me this year is I began to have a greater recognition and appreciation for. Let's go back to our founders, Ed and Jackie Preston. You know, back in 1952, they they started this business.

Dan: [00:17:18] And so when I came on board in '96. There was a a few things that stood out to me. A phone never rang more than three times because it was disrespectful to the customer to make them have to listen to the ring on the phone more than three times. It was just a thing. Everybody here still knows by the time that there is a fourth ring, everybody in the plant is running for a form because it shouldn't ring more than three times. That system still by Mr President from the beginning.

Dan: [00:17:46] The other thing is when we have meetings here and we have a lot of meals at this company, the first an Ed or Jackie Ed's passed away now. And anytime we had a meal, they always eat last. They always insisted everybody else. You go first. We go laugh. Simon Sinek wrote a book. Leaders eat last. And when I read that, I saw Jackie. But I still believe it's all part of what Deming. His respect that he had for people. And and I saw so much of that and have seen so much in adding Jackie over the years that respect for people to make sure that the people in this company are taken care of first.

Dan: [00:18:30] And how so? So I would read, learn and then recognize and appreciate what already exists around you. And then I would start, I think, trying to implement the things that you were there.

Tripp: [00:18:43] Brian -do you have something to add.

Brian: [00:18:46] Not really know that.

Tripp: [00:18:50] No, that's fine. So let me ask you. Just kind of a broader question. I guess it looked like you guys sell globally, correct?

Dan: [00:19:00] Mostly in the United States. OK. If something goes outside of the United States and through our customers, not not directly from us to a customer outside the United States.

Tripp: [00:19:12] Ok. So has the environment changed much? I mean, there's a lot going on economically for your company. Is it gotten a lot better or is it kind of been stable all along or what's it like out there as far as manufacturing goes?

Dan: [00:19:28] So this year there's been a softening in general across pretty much all of the industries that we serve.

Dan: [00:19:37] And we we serve a number of them. Most of our business is relatively local. About 70 to 73 percent is in Michigan and the rest is either in southern Indiana or Texas. Shooting down that quarter in general have softened. And I just saw the numbers today that manufacturing in the third quarter actually went up a touch, which surprised me because we haven't seen it and I haven't heard that from our suppliers, to be quite honest with you. But one of the things that we've tried to do over the years, as we called our lean journey or on our shifting gears and to we actually trademarked a year or two ago the term system, Micron, because the reason people come here, the reason three thousand people visited are to see our systems. We had fire departments, health care, the company that created the resistor. And A we've had people from all over the world come to see how we schedule production.

Dan: [00:20:39] We have no mid-level management, how we have total flex time. People can decide which days they work, what hours they work. The whole nine yards. And and so people have come from all over to see how well how can we manage a company to where there are no bosses. There's a movie that tells people what to do. Brian, are the managers of quality in manufacturing and there's there's an engineering manager. We're responsible for the systems and making sure the people, the resources are there, of course. But it's it's really there's so much autonomy that people have. And and this year, really, over the last three or four years that we've been using the Toyota car, it really began to teach us a better understanding of the kind of calls PDCA.

Dan: [00:21:31] And that PDSA. So we use that language mostly because of that. But because of that, we began to emphasize every conversation. What did we learn? What did we learn? I think if I were to look back in the three last three years, the number one question that we ask yourself is what did we learn? Fill in the blank on whatever the heck it is that we're talking about. So I would I would dare say that the Deming philosophy is all about what have you learned? And we've embraced that.

Tripp: [00:22:04] And you guys have mentioned the lean journey that you kind of started on before you kind of got into Deming. What do you see as kind of the differences between them or or how did they maybe synergistically and engage with each other as you work through this or or what's happened with this this lean journey still continuing that as the Deming philosophy, enhance it. What's your view?

Dan: [00:22:34] So. I think that. Like most things in life, it's the perspective you choose. And I think that you can and perhaps many companies have chosen the perspective of Lean as the elimination of waste. And of course, that's an element of it.

Dan: [00:23:00] But I believe and we've used that language here a lot, but I believe truly that what we've tried to do with our lean journey is to best use our resources. So Dr. Deming talks about optimization of processes, right? We haven't used that language exactly a lot, but that's what our journey has been about. How do we optimize what we do? How do we create standards, stick to improve the standard and make things the lives of our people better?

Dan: [00:23:28] And that from day one, when we are first meeting about why are we going to take this lean journey? Way back in August of 2000, our management team said it is for one reason and that it is to make the lives of our people better and.

Dan: [00:23:46] From that day on, I felt as long as we have that focus. We're on the right path. And and so as we went through our lean journey, we were. Awarded the Shingo Silver Medallion for operational excellence back in 2008 93. And it's referred to as the Nobel Prize of Business or Manufacturing by Business Week. And that was nice to get. It was kind of a confirmation that we're on a good path, but the best thing about us told us all things we could do better. And so we tried to embrace them. And so on. As we learned more about the teachings of Dr. Deming, here's a thing that we weren't using properly our entire lean during that we're only now starting to learn and use much better.

Dan: [00:24:39] And that is the understanding of variation that Brian mentioned earlier or in control charts and we hadn't used. I don't know if we used a control Chart. Fifteen years probably that are 20 0 0 0. And now we really are. We're embracing the heck out of that. And we're beginning to understand where we have to measure data and where you continue on.

Dan: [00:25:02] Probably the greatest weakness, though, for us, the difference between how we treated women and what we're learning from Dr. Deming, though, is we are making a lot of change and we're necessarily tracking whether or not that change was an improvement towards the saying we needed improvement on. Right. Yeah. In that corner of the planet might look better now, but is it truly improving anything that's going to help the customer? And we lost sight of that for a while, I believe. And I think we're getting on back, Brian, to everything else then was pretty good a.

Brian: [00:25:37] The appreciation of a system as as we did the room. I think we learned more about systems because you have to diagram them out and understand the interactions between them. And so that kind of opened our eyes and just happened to fit in with a kind of reconfirms that Dr. Deming needs says. You should understand your system as good as you can. I think it also psychology. You know, in the beginning there are resistors because change is scary. And I'm sure some people wonder if you truly mean it. Or is that just the passing thing this month? And so you understand as you push that journey through and you get the buy in from people that that were once resistors. OK, that's cool. You get to watch and growth in your own people. You learn how to achieve that growth faster. Either by learning from your mistakes or the occasional times we we somehow did it right. So I thought all of that. There is a consistency between Lean and Dr. Deming. I think I can see that.

Tripp: [00:26:50] Okay. And Brian, you have to ask, because you mentioned that you kind of got into variation, you know, years ago or maybe even a couple of decades ago. And we're using it, you know, in what's different today, what it what it sounds like. You started into it kind of got away from it and then went back to it. What would take me a little bit on that journey?

Brian: [00:27:13] Long ago when I was when I first was introduced to it, we were trying to everything classic's and we wanted to learn how to build Dai's better. So is there a way to design a dye with more success by the time you're done, by the time you're finished? And I couldn't believe how much statistics help you in design. So that was kind of low hanging fruit and. So it's fun to play with.

Brian: [00:27:43] But we didn't necessarily use it in day to day production at that facility I worked with.

Tripp: [00:27:49] OK,.

Brian: [00:27:50] So then I. I moved on to Micron and that was my first attempt. OK. We don't use it to design our process, but we do use it to monitor our process. And back then, it was sort of driven by customers. They were requiring statistical data. And that's fine. But what's more, fighing are more fun to actually learn that you can predict your process. But I find that fascinating every day.

Brian: [00:28:19] So we're into that pretty deep for about four or five years. And for some reason, the customers decided to let those requirements go. And somehow that that seemed to be it took the wind out of the sails of that process.

Brian: [00:28:37] And so for some time, we didn't use statistics for quite some time. And then I would say in the last five or six years. We are doing more and more statistical studies and realizing once again the benefits of doing so. And now we're actually applying it to management processes rather than just parts or machines. And we're finding that. That is even more fascinating than than going out new in capability studies out next to a fancy.

Dan: [00:29:10] I think though, one of the stark differences between then and now is we did it because the customer demanded it and the sooner they stop demanding it, we stop doing it tells you how mature where I am right now.

Dan: [00:29:27] Now we go this beginning. We realize, as Brian said, it's helping us understand our management systems in ways we never would have dreamt before. And we're doing it because it's the right thing to do and you're learning from it. And we're the kind of company that there's no doubt in my mind that sometime very nearly down the road, we're going to be pushing this to our customers to try to do the same thing as we did that with our lean systems. When when we first started Dileep Journey by time 2003 rolled around, we had made a lot of changes and we realized that one of our customers had any idea what lean was. And we we began to bump up into. We can only improve our systems so well if we can't tie it to where our customers are demanding or needing from us. So we went on this magical mystery tour out to our customers for three years to try to see how can we link what we're doing to what you might need. And pretty soon, all of our customers want to delinked their systems to ours. And we went from like 16 percent of what we built was on some kind of pulse system to 68 percent within those three years. And it was an amazing thing because when they began to recognize what it could do for them and it helped us help them, it was great. So we were still and we began then to take what we've learned and what we knew and share it with the customer. So here's just another thing that as we learn more, I can see that we're going to share it with the customers because it will help them help us.

Tripp: [00:31:07] Very cool. So my last question for you guys is, is my typical one, which is. Is there anything that we've talked about or that you've responded to that you'd like to make a clarification of? Or is there any question I didn't ask that you wish I would have?

Dan: [00:31:28] That's really that's a great question.

Dan: [00:31:33] I know that they're the Deming Institute is reaching out to educational organizations across the country. I'm not aware of any of that in Michigan. There are individuals, like I mentioned Dennis a few times now that is trying to help industry. But it's important that we believe that the school systems are help. Few years ago, Mike Rather, the author of The Toyota Kata, was gracious enough to stop that. Mike Brown wandered through the plant. And then I was so bold as to invite him to teach the school that my kids went to grade school or how to do the participate in the Kata, which of course, as I mentioned, includes the whole PDCA cycle of improvements. And he did so and I thought it was a fantastic session. And it began the thinking, how can we get more AUTHERS? How can we get more people helping teach the schools that teach students how to be more critical thinkers? So I think that that would be something of. All certain interests of manufacturers all over the country. Here, as we try to help, you know, he knows the skills gap all the time, right?

Dan: [00:32:53] Mostly is a critical thinking gap in our opinion. We can teach the skill. So anything like that. We would love to see and hear more about it as time goes by.

Tripp: [00:33:03] Very cool, Brian. Thoughts? Last thoughts.

Brian: [00:33:07] Yeah, I don't remember who you were talking to and one of your podcasts, but your guest. You ask the question of them and I'm going to paraphrase. Do you think the Deming Philosophy is growing or shrinking or remaining the same. And he said he did not believe it to be growing.

Brian: [00:33:29] My guess, I was disappointed. Whoever your guest was, it seemed like a person that would probably know that answer better than I did. And that made me sad to think. And so I am curious, as Dan just said, you know, not only getting to the local school systems, but also the business schools. What is what is coming out of the business schools now? The people that we're going to hire soon?

Brian: [00:33:56] And then how do we get even further ahead, as Dan said? And get this all the way down to how do you teach young people to think in a better way? And.

Dan: [00:34:08] It's important for us. So earlier this year, Ryan and I both referred to CQI Academy that we had taken to learn more about Dr. Demings work, and I had coordinated through an organization called Discover Manufacturing here in West Michigan.

Dan: [00:34:26] They coordinated and I see it an industry led collaborative where four of our companies, 19 different people or 20, went to this class and one was in carbon composites, another one furniture, and there another machining company like ours.

Dan: [00:34:45] And it didn't matter that we were basically different industries and different walks of life. It was somebody from shipping to, you know, my position, brines as managers and everything in between. And it was a fantastic way to learn these collaboratives of different companies. So we're intending to do it again this next spring. I'm signed up as the co-lead for Discovery Manufacturing and make sure you do. And that's that's our contribution to try to make sure that we're spreading the teachings of Dr. Demings in West Michigan here, because regardless, I'm not sure what else we can do other than it here. We have tours every two or three weeks and people who come see it and we're trying to help this. I'll see more companies learn about it. So I hope that your listeners and companies that are getting involved open the doors and bring people in and show what they're learning. It doesn't matter how minor it is. Teach what you're learning and then try to get other companies together to do the same.

Tripp: [00:35:53] And that's sage advice. We appreciate it. Well, Dan and Bryan, we certainly appreciate you being part of the Deming Institute podcast.

Dan: [00:36:04] Well, thank you, Tripp. Greatly appreciate it.

Tripp: [00:36:08] Thank you for listening to the Deming Institute podcast. Stay updated on the latest blogs, podcasts, programs and other activities at Deming dot org.

In our 6th Interview episode, Plant Manager Dan Vermeesch and Quality Manager Brain Hoff discuss their Deming Journey. Topics include a discussion on variation and getting the Deming Philosophy into the education.

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Deming Institute Podcast Interview

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Micron Manufacturing

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History of Micron Manufacturing

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Dan Vermeesch

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Brian Hoff

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Dr. Deming at Micron

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Variation

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Eliminating Performance Reviews at Micron

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Struggles of Working with the Deming Philosophy

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Micron Gives Advice on Adopting the Deming Philosophy

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Shingo Silver Medallion

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Variation a Key to Micron Improvement

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Deming Needed in Education

Tripp: [00:00:12] In this Deming Institute interview, I speak with Dan Vermeesch and Brian Hoff of Μ Manufacturing in Grand Rapids, Michigan. We discuss the history of Μicron, their improvement journey and how the Dunning philosophy is affecting this journey today.

Tripp: [00:00:35] Hi, I'm Tripp Babbitt, host of the Deming Institute podcast. Our guests today are a couple of gentlemen from Micron Manufacturing, Dan Veermsch and Bryan Hoff. Welcome, gentlemen.

Dan: [00:00:48] Hi, Tripp. Thanks for having us.

Tripp: [00:00:50] Very good. So first of all, micro manufacturing I'm not familiar with it. Won't want to share a little bit about what Micron Manufacturing does and a little bit about both your gentlemans role in Micron churn, Micron manufacturing as it was using machine products company in Grand Rapids, Michigan.

Dan: [00:01:10] It's been in business since 1952, Ed and Jackie Preston founded it back then and until just a few months ago, Jackie Preston still came in every day, five days a week. She just turned ninety one a couple of weeks ago and she hasn't been in in a few months. But she was here every day until then. And it was great because her son currently is the president at Micron. And we have a niece and nephew that work here. And the nephew has a 5 year old daughter that comes in on Saturday and plays on a computer. So one of the best parts of the story of Micron is we have four generations in this building every week.

Dan: [00:01:51] And it really is part of the story that's important because there's a lot of family focus here at Micron that that's important to us. So I am the plant manager, have been the plant managers since 97 and also the lean champion that has tried to be the architect of some of the various improvements systems that we have had since the year 2000 is when we really begin implementing our transformational change. So I'll let Brian introduce you.

Tripp: [00:02:26] Okay.

Brian: [00:02:27] I'm Brian Hoff. I'm a quality manager at Micron. This would be my twenty second year with Micron. And as Dan said, it's around 2001. We began to be to transform our journey from kind of an old school business model to trying to adapt what is the best way to make change and improvement. And it's been an amazing journey. And lately we seem to have encountered Mr. Deming once again. And I guess I'm mature enough to understand it better than I did 20 years ago. And I'm using him almost daily to try to influence the decisions I make each day.

Tripp: [00:03:13] Very good. And where are you guys located?

Dan: [00:03:17] Grand Rapids, Michigan. OK. We're on a dead end street in the northwest corner of Grand Rapids, Michigan. So that's that's always part of my favorite part of the story here is we're kind of located on the edge to nothing. And despite all that, our folks here have made so many great changes over the years that we've had thousands of people from, I think, 26 states and eight countries that have come to visit us to see the systems that have been put into place over the years. And we're only a 40 person company. Twenty eight thousand square feet. So we're just a small about on the map that that over the years have made a big ripple in the pond. The precision machining industry. And it is exciting that we've got such a great group of folks that have not only made change, but we've made a lot of improvements over the years. But part of our story that we'll get into and will allow is we're making a lot of change, but we kind of lost sight of whether or not some of that was improvement. So we could see a lot of change around here. But the dials stopped moving after awhile. And so we had to go back to the drawing board. And that drawing board was Dr. Demings work.

Dan: [00:04:35] Okay, very good. Well, let's pick it up from there. So how did you guys come across Dr. Demings work? It sounds like maybe you initially knew Dr. Deming then kind of got away from it. So once you share a little bit about your journey there.

Brian: [00:04:52] So this, Brian, and back when I was a young 20 some year old, I happened to go to a statistics course, and during that course the instructor had mentioned Juran and Deming. So I began with Juran and in Juran Zone books, he mentioned Dr. Deming, so once I completed listening to the doctor, Mr. Grant, I read out of the crisis and.

Brian: [00:05:18] I don't know that it made complete sense to me at the time, but it did. The thing that got me was the study of variation. But so I spent five or six years diving kind of deep into statistics and I made some headway that wasn't I wasn't at Micron at that time. I was I was in the plastics industry. So when I joined my Mike Brown back in ninety one and.

Brian: [00:05:46] We were able to use some of the statistical tools so that in a way I was holding on to some old blood. Dr. Deming talked about variation. But I wasn't I wasn't truly knowledgeable about profound knowledge and the way to think of all of that. And then I admit to somehow I lost track of Dr. Deming for a decade or more. And then later, when Μicron started doing its deep transformation, Dr. Deming started coming to my mind more often. So I re-read the books again. And since then, it seems as though. There was a trajectory of adopting a little more of Dr. Deming, and then recently we seem to have found a new gear in regards to appreciating what he said.

Dan: [00:06:41] So a number of years ago, maybe the early 2000s. Brian and I have had a lot of conversations over our years of transformation. We always called it our lean journey. And that's that's how we knew it. But he would bring up regularly his views on variation. And then I asked, would you come up with all this? And we mentioned Dr. Deming and I need to learn more about this.

Dan: [00:07:07] Never, never really put forth the effort to do so. Until I was at a conference in Columbus, Ohio, I think about eight or nine years ago, and the speaker talked about the 14 points. It seems like I've heard of those in the past. Any you talk further about the doing performance evaluations and the disrespect that came from it. It just so happened to be the high end and pushing performance reviews here created a very in depth system. We're doing them quarterly. We're doing all this stuff and I hated every minute of it. And I couldn't put my finger on what was it that I felt that was wrong with it until I heard the speaker say just how disrespectful Dr. Deming felt that they were and why that day.

Dan: [00:07:58] I decided before I left that meeting, we were never doing another one. And I came back and I told our management team it's called team strategy. I apologize for pushing it so hard for so many years and shoved it down everybody's throat. And today we stop. I. I wish I would have gotten a picture of the room on that day, because I think the shock phase, after pushing it so hard that doing a complete 180, but it truly was like like seeing the sun come up because it put words to the feeling that was growing in me, that this is just wrong because half the people were walking out of the room feeling they were below average. Right. Who do you want to feel that way? And that was the day that I thought, I need to learn more about this guy.

Tripp: [00:08:46] Very interesting. So. So, yeah, go ahead.

Dan: [00:08:50] Oh, I'm sorry. So I was a few years after that that I don't and I can't recall right now how I caught wind of the Deming research conference in Fordham University in New York. And we've done a lot of presentations, like I mentioned earlier, sharing our lead story. And so I thought I'll submit and see us there is interested in her interest in hearing our story at the research conference. And then I was honored to be selected to do that. And.

Dan: [00:09:23] It was then that I met Dr. Demings, daughter and grandson, great grandson, and and heard everybody else that was speaking there, it truly became inspired by what I heard. And and Brian joined me on that trip and I brought my 15 year old daughter at the time and I thought because the story was about this whole story of Μicron. And I just wanted. I thought she needs to hear what grandpa and grandma created because I didn't mention earlier, I'm the son in law of the founders, but so I brought her with me.

Dan: [00:09:58] And it turns out she was the youngest attendee at a DME conference, I think, in the history of the den. And so Kevin and his wife is her name's Judy, I think, right? Yep. Yep. So they embraced her so much. I was really touched by that. So when the conference came to Michigan State University, where my daughter attends now at the conference, we walked in and she was just going to visit and say hi and whatever. And they made her so welcome. And got her a badge and invited her to attend a conference and everything. And it was really touching that they had a remembered her and they have really embraced a young person. And she's brought it up so many times. And and it's just that to me, that whole story just adds flavor to what I believe is the Deming community that I'm beginning to learn more about. So it's not just about the things he taught, but it's I'm beginning to see that the people that truly understand them are beginning to it. It's a group that we need to hang out with more. Right.

Tripp: [00:11:06] Very good..

Tripp: [00:11:07] So so let me ask you guys, when you started in to the Deming philosophy or as you've worked with with it, what things have you either personally struggle with or maybe even the organization has struggled with?

Dan: [00:11:23] So for me, I mentioned it again today in our strategy meeting to Brian and others that my 2019 transformation that came earlier this year when Dennis Sergent was the instructor of our Deming CQ Academy is what he calls it. And there was so much reference to improve it. So I love the statement. All premier requires change. Not all change results in improvement. So that was great to hear her have heard that before. But. I am a numbers guy. True and true on the facts and figures and dates and deadlines, you gotta go. You know, maybe that's part of being a plant manager. I don't know, but I begin to understand that.

Dan: [00:12:18] And then we've done a great job recently with our team strategy meetings. We are going to take a step in the right direction every day. And we we don't hold our feet to the fire like we used to about by this date. This thing has, you know, those kinds of things that the made up numbers of.

Dan: [00:12:35] You got to hit this goal by this day. We still have some of that. But there's far less focus on that than there was coming into 2019. And I struggle with it every day, every day that I bite my tongue and say, don't kick a no, don't create a no, don't push a number. Push the improvement and true change towards what we are looking to accomplish.

Dan: [00:13:01] And it's it's liberating, to say the very least. And again, it's humbling. It's almost like that day came back and say and said, when I do another performance evaluations offered me by longshot that because it's such a one idea who I am.

Tripp: [00:13:18] Interesting. Brian. Brian, how about you?

Brian: [00:13:22] Well, first, I want to attest to watching Dan's struggle with Martin.

Tripp: [00:13:28] Okay, so you've witnessed it. Okay, I got it. I think me.

Brian: [00:13:36] Oh, recently I encountered a. A customer had a problem, and normally if if we have material here that we asked to re-inspect, we learn how to do it. And we show another person how. And we call that a training system.

Brian: [00:13:53] And for some reason, and this particular incident, I decided instead of training the way I always have, I'm going to do it different. Because Mr. Deming said you should look harder at your training systems. There are likely problems there. And so I decided what would be a better way. And when I was done, it literally opened my mind to the amount of variation in a training system.

Brian: [00:14:22] Either doesn't pay attention to or creates all by itself, and so that would be a thing that recently happened to me in regards to understanding better, something that Mr. Deming talked about.

Tripp: [00:14:39] Very good. So here's a question for both of you. And it does matter what order that you respond. But if you were if you're a manufacturer, it's, say, listening to this podcast episode and you were thinking about this. What are some of the maybe, I don't know, pointers that you might give them about going to this philosophy, Will? What are the steps that you think they might go through or what advice might you have?

Dan: [00:15:10] That's a very good question. I think that as in most things, learning has to take place. And for me and for Brian, that fact he's got out of the crisis in his hands now, I've got some sticky notes in it.

Dan: [00:15:25] I get it. I always give Ryan a little ribbing because I call his Brian Dowling Bible here because he carries with him everywhere. I don't think I'd recognize him if he came to work about the thing in his hands. I think you have to start there. And I didn't start there. I just read the New Economics. In fact, I just got done with it in recent ago. First book I ever read.

Dan: [00:15:52] And then I have a long time ago, before I went to the Research Council that I read online, I learned more. I loved the history. I loved the fact that he grew up in a farming area and studied. How should it be? Because I grew up on of farm in Michigan here. So that really all resonated with me. And as I began to learn his story and his half life begins to patch together a lot of thoughts about how this may have all developed for him. And I want the history part of it. That's great. So I would suggest people be read about him and listen to these podcasts for sure.

Dan: [00:16:33] Look online if the educational beginning. But it was instrumental earlier this year. After all this time, haven't taken the Dennis Surgeons CGI Academy that really gave us this. It's what we did, guys. And I have to believe these types of sessions are all over the United States for people to be able to learn more and participate in groups. Exactly. And implement exactly what he's what he's trying to implement. And so through that, one of the things that's occurred to me this year is I began to have a greater recognition and appreciation for. Let's go back to our founders, Ed and Jackie Preston. You know, back in 1952, they they started this business.

Dan: [00:17:18] And so when I came on board in '96. There was a a few things that stood out to me. A phone never rang more than three times because it was disrespectful to the customer to make them have to listen to the ring on the phone more than three times. It was just a thing. Everybody here still knows by the time that there is a fourth ring, everybody in the plant is running for a form because it shouldn't ring more than three times. That system still by Mr President from the beginning.

Dan: [00:17:46] The other thing is when we have meetings here and we have a lot of meals at this company, the first an Ed or Jackie Ed's passed away now. And anytime we had a meal, they always eat last. They always insisted everybody else. You go first. We go laugh. Simon Sinek wrote a book. Leaders eat last. And when I read that, I saw Jackie. But I still believe it's all part of what Deming. His respect that he had for people. And and I saw so much of that and have seen so much in adding Jackie over the years that respect for people to make sure that the people in this company are taken care of first.

Dan: [00:18:30] And how so? So I would read, learn and then recognize and appreciate what already exists around you. And then I would start, I think, trying to implement the things that you were there.

Tripp: [00:18:43] Brian -do you have something to add.

Brian: [00:18:46] Not really know that.

Tripp: [00:18:50] No, that's fine. So let me ask you. Just kind of a broader question. I guess it looked like you guys sell globally, correct?

Dan: [00:19:00] Mostly in the United States. OK. If something goes outside of the United States and through our customers, not not directly from us to a customer outside the United States.

Tripp: [00:19:12] Ok. So has the environment changed much? I mean, there's a lot going on economically for your company. Is it gotten a lot better or is it kind of been stable all along or what's it like out there as far as manufacturing goes?

Dan: [00:19:28] So this year there's been a softening in general across pretty much all of the industries that we serve.

Dan: [00:19:37] And we we serve a number of them. Most of our business is relatively local. About 70 to 73 percent is in Michigan and the rest is either in southern Indiana or Texas. Shooting down that quarter in general have softened. And I just saw the numbers today that manufacturing in the third quarter actually went up a touch, which surprised me because we haven't seen it and I haven't heard that from our suppliers, to be quite honest with you. But one of the things that we've tried to do over the years, as we called our lean journey or on our shifting gears and to we actually trademarked a year or two ago the term system, Micron, because the reason people come here, the reason three thousand people visited are to see our systems. We had fire departments, health care, the company that created the resistor. And A we've had people from all over the world come to see how we schedule production.

Dan: [00:20:39] We have no mid-level management, how we have total flex time. People can decide which days they work, what hours they work. The whole nine yards. And and so people have come from all over to see how well how can we manage a company to where there are no bosses. There's a movie that tells people what to do. Brian, are the managers of quality in manufacturing and there's there's an engineering manager. We're responsible for the systems and making sure the people, the resources are there, of course. But it's it's really there's so much autonomy that people have. And and this year, really, over the last three or four years that we've been using the Toyota car, it really began to teach us a better understanding of the kind of calls PDCA.

Dan: [00:21:31] And that PDSA. So we use that language mostly because of that. But because of that, we began to emphasize every conversation. What did we learn? What did we learn? I think if I were to look back in the three last three years, the number one question that we ask yourself is what did we learn? Fill in the blank on whatever the heck it is that we're talking about. So I would I would dare say that the Deming philosophy is all about what have you learned? And we've embraced that.

Tripp: [00:22:04] And you guys have mentioned the lean journey that you kind of started on before you kind of got into Deming. What do you see as kind of the differences between them or or how did they maybe synergistically and engage with each other as you work through this or or what's happened with this this lean journey still continuing that as the Deming philosophy, enhance it. What's your view?

Dan: [00:22:34] So. I think that. Like most things in life, it's the perspective you choose. And I think that you can and perhaps many companies have chosen the perspective of Lean as the elimination of waste. And of course, that's an element of it.

Dan: [00:23:00] But I believe and we've used that language here a lot, but I believe truly that what we've tried to do with our lean journey is to best use our resources. So Dr. Deming talks about optimization of processes, right? We haven't used that language exactly a lot, but that's what our journey has been about. How do we optimize what we do? How do we create standards, stick to improve the standard and make things the lives of our people better?

Dan: [00:23:28] And that from day one, when we are first meeting about why are we going to take this lean journey? Way back in August of 2000, our management team said it is for one reason and that it is to make the lives of our people better and.

Dan: [00:23:46] From that day on, I felt as long as we have that focus. We're on the right path. And and so as we went through our lean journey, we were. Awarded the Shingo Silver Medallion for operational excellence back in 2008 93. And it's referred to as the Nobel Prize of Business or Manufacturing by Business Week. And that was nice to get. It was kind of a confirmation that we're on a good path, but the best thing about us told us all things we could do better. And so we tried to embrace them. And so on. As we learned more about the teachings of Dr. Deming, here's a thing that we weren't using properly our entire lean during that we're only now starting to learn and use much better.

Dan: [00:24:39] And that is the understanding of variation that Brian mentioned earlier or in control charts and we hadn't used. I don't know if we used a control Chart. Fifteen years probably that are 20 0 0 0. And now we really are. We're embracing the heck out of that. And we're beginning to understand where we have to measure data and where you continue on.

Dan: [00:25:02] Probably the greatest weakness, though, for us, the difference between how we treated women and what we're learning from Dr. Deming, though, is we are making a lot of change and we're necessarily tracking whether or not that change was an improvement towards the saying we needed improvement on. Right. Yeah. In that corner of the planet might look better now, but is it truly improving anything that's going to help the customer? And we lost sight of that for a while, I believe. And I think we're getting on back, Brian, to everything else then was pretty good a.

Brian: [00:25:37] The appreciation of a system as as we did the room. I think we learned more about systems because you have to diagram them out and understand the interactions between them. And so that kind of opened our eyes and just happened to fit in with a kind of reconfirms that Dr. Deming needs says. You should understand your system as good as you can. I think it also psychology. You know, in the beginning there are resistors because change is scary. And I'm sure some people wonder if you truly mean it. Or is that just the passing thing this month? And so you understand as you push that journey through and you get the buy in from people that that were once resistors. OK, that's cool. You get to watch and growth in your own people. You learn how to achieve that growth faster. Either by learning from your mistakes or the occasional times we we somehow did it right. So I thought all of that. There is a consistency between Lean and Dr. Deming. I think I can see that.

Tripp: [00:26:50] Okay. And Brian, you have to ask, because you mentioned that you kind of got into variation, you know, years ago or maybe even a couple of decades ago. And we're using it, you know, in what's different today, what it what it sounds like. You started into it kind of got away from it and then went back to it. What would take me a little bit on that journey?

Brian: [00:27:13] Long ago when I was when I first was introduced to it, we were trying to everything classic's and we wanted to learn how to build Dai's better. So is there a way to design a dye with more success by the time you're done, by the time you're finished? And I couldn't believe how much statistics help you in design. So that was kind of low hanging fruit and. So it's fun to play with.

Brian: [00:27:43] But we didn't necessarily use it in day to day production at that facility I worked with.

Tripp: [00:27:49] OK,.

Brian: [00:27:50] So then I. I moved on to Micron and that was my first attempt. OK. We don't use it to design our process, but we do use it to monitor our process. And back then, it was sort of driven by customers. They were requiring statistical data. And that's fine. But what's more, fighing are more fun to actually learn that you can predict your process. But I find that fascinating every day.

Brian: [00:28:19] So we're into that pretty deep for about four or five years. And for some reason, the customers decided to let those requirements go. And somehow that that seemed to be it took the wind out of the sails of that process.

Brian: [00:28:37] And so for some time, we didn't use statistics for quite some time. And then I would say in the last five or six years. We are doing more and more statistical studies and realizing once again the benefits of doing so. And now we're actually applying it to management processes rather than just parts or machines. And we're finding that. That is even more fascinating than than going out new in capability studies out next to a fancy.

Dan: [00:29:10] I think though, one of the stark differences between then and now is we did it because the customer demanded it and the sooner they stop demanding it, we stop doing it tells you how mature where I am right now.

Dan: [00:29:27] Now we go this beginning. We realize, as Brian said, it's helping us understand our management systems in ways we never would have dreamt before. And we're doing it because it's the right thing to do and you're learning from it. And we're the kind of company that there's no doubt in my mind that sometime very nearly down the road, we're going to be pushing this to our customers to try to do the same thing as we did that with our lean systems. When when we first started Dileep Journey by time 2003 rolled around, we had made a lot of changes and we realized that one of our customers had any idea what lean was. And we we began to bump up into. We can only improve our systems so well if we can't tie it to where our customers are demanding or needing from us. So we went on this magical mystery tour out to our customers for three years to try to see how can we link what we're doing to what you might need. And pretty soon, all of our customers want to delinked their systems to ours. And we went from like 16 percent of what we built was on some kind of pulse system to 68 percent within those three years. And it was an amazing thing because when they began to recognize what it could do for them and it helped us help them, it was great. So we were still and we began then to take what we've learned and what we knew and share it with the customer. So here's just another thing that as we learn more, I can see that we're going to share it with the customers because it will help them help us.

Tripp: [00:31:07] Very cool. So my last question for you guys is, is my typical one, which is. Is there anything that we've talked about or that you've responded to that you'd like to make a clarification of? Or is there any question I didn't ask that you wish I would have?

Dan: [00:31:28] That's really that's a great question.

Dan: [00:31:33] I know that they're the Deming Institute is reaching out to educational organizations across the country. I'm not aware of any of that in Michigan. There are individuals, like I mentioned Dennis a few times now that is trying to help industry. But it's important that we believe that the school systems are help. Few years ago, Mike Rather, the author of The Toyota Kata, was gracious enough to stop that. Mike Brown wandered through the plant. And then I was so bold as to invite him to teach the school that my kids went to grade school or how to do the participate in the Kata, which of course, as I mentioned, includes the whole PDCA cycle of improvements. And he did so and I thought it was a fantastic session. And it began the thinking, how can we get more AUTHERS? How can we get more people helping teach the schools that teach students how to be more critical thinkers? So I think that that would be something of. All certain interests of manufacturers all over the country. Here, as we try to help, you know, he knows the skills gap all the time, right?

Dan: [00:32:53] Mostly is a critical thinking gap in our opinion. We can teach the skill. So anything like that. We would love to see and hear more about it as time goes by.

Tripp: [00:33:03] Very cool, Brian. Thoughts? Last thoughts.

Brian: [00:33:07] Yeah, I don't remember who you were talking to and one of your podcasts, but your guest. You ask the question of them and I'm going to paraphrase. Do you think the Deming Philosophy is growing or shrinking or remaining the same. And he said he did not believe it to be growing.

Brian: [00:33:29] My guess, I was disappointed. Whoever your guest was, it seemed like a person that would probably know that answer better than I did. And that made me sad to think. And so I am curious, as Dan just said, you know, not only getting to the local school systems, but also the business schools. What is what is coming out of the business schools now? The people that we're going to hire soon?

Brian: [00:33:56] And then how do we get even further ahead, as Dan said? And get this all the way down to how do you teach young people to think in a better way? And.

Dan: [00:34:08] It's important for us. So earlier this year, Ryan and I both referred to CQI Academy that we had taken to learn more about Dr. Demings work, and I had coordinated through an organization called Discover Manufacturing here in West Michigan.

Dan: [00:34:26] They coordinated and I see it an industry led collaborative where four of our companies, 19 different people or 20, went to this class and one was in carbon composites, another one furniture, and there another machining company like ours.

Dan: [00:34:45] And it didn't matter that we were basically different industries and different walks of life. It was somebody from shipping to, you know, my position, brines as managers and everything in between. And it was a fantastic way to learn these collaboratives of different companies. So we're intending to do it again this next spring. I'm signed up as the co-lead for Discovery Manufacturing and make sure you do. And that's that's our contribution to try to make sure that we're spreading the teachings of Dr. Demings in West Michigan here, because regardless, I'm not sure what else we can do other than it here. We have tours every two or three weeks and people who come see it and we're trying to help this. I'll see more companies learn about it. So I hope that your listeners and companies that are getting involved open the doors and bring people in and show what they're learning. It doesn't matter how minor it is. Teach what you're learning and then try to get other companies together to do the same.

Tripp: [00:35:53] And that's sage advice. We appreciate it. Well, Dan and Bryan, we certainly appreciate you being part of the Deming Institute podcast.

Dan: [00:36:04] Well, thank you, Tripp. Greatly appreciate it.

Tripp: [00:36:08] Thank you for listening to the Deming Institute podcast. Stay updated on the latest blogs, podcasts, programs and other activities at Deming dot org.

In our 6th Interview episode, Plant Manager Dan Vermeesch and Quality Manager Brain Hoff discuss their Deming Journey. Topics include a discussion on variation and getting the Deming Philosophy into the education.

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Deming Institute Podcast Interview

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Micron Manufacturing

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History of Micron Manufacturing

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Dan Vermeesch

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Brian Hoff

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Dr. Deming at Micron

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Variation

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Eliminating Performance Reviews at Micron

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Struggles of Working with the Deming Philosophy

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Micron Gives Advice on Adopting the Deming Philosophy

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Shingo Silver Medallion

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Variation a Key to Micron Improvement

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Deming Needed in Education

Tripp: [00:00:12] In this Deming Institute interview, I speak with Dan Vermeesch and Brian Hoff of Μ Manufacturing in Grand Rapids, Michigan. We discuss the history of Μicron, their improvement journey and how the Dunning philosophy is affecting this journey today.

Tripp: [00:00:35] Hi, I'm Tripp Babbitt, host of the Deming Institute podcast. Our guests today are a couple of gentlemen from Micron Manufacturing, Dan Veermsch and Bryan Hoff. Welcome, gentlemen.

Dan: [00:00:48] Hi, Tripp. Thanks for having us.

Tripp: [00:00:50] Very good. So first of all, micro manufacturing I'm not familiar with it. Won't want to share a little bit about what Micron Manufacturing does and a little bit about both your gentlemans role in Micron churn, Micron manufacturing as it was using machine products company in Grand Rapids, Michigan.

Dan: [00:01:10] It's been in business since 1952, Ed and Jackie Preston founded it back then and until just a few months ago, Jackie Preston still came in every day, five days a week. She just turned ninety one a couple of weeks ago and she hasn't been in in a few months. But she was here every day until then. And it was great because her son currently is the president at Micron. And we have a niece and nephew that work here. And the nephew has a 5 year old daughter that comes in on Saturday and plays on a computer. So one of the best parts of the story of Micron is we have four generations in this building every week.

Dan: [00:01:51] And it really is part of the story that's important because there's a lot of family focus here at Micron that that's important to us. So I am the plant manager, have been the plant managers since 97 and also the lean champion that has tried to be the architect of some of the various improvements systems that we have had since the year 2000 is when we really begin implementing our transformational change. So I'll let Brian introduce you.

Tripp: [00:02:26] Okay.

Brian: [00:02:27] I'm Brian Hoff. I'm a quality manager at Micron. This would be my twenty second year with Micron. And as Dan said, it's around 2001. We began to be to transform our journey from kind of an old school business model to trying to adapt what is the best way to make change and improvement. And it's been an amazing journey. And lately we seem to have encountered Mr. Deming once again. And I guess I'm mature enough to understand it better than I did 20 years ago. And I'm using him almost daily to try to influence the decisions I make each day.

Tripp: [00:03:13] Very good. And where are you guys located?

Dan: [00:03:17] Grand Rapids, Michigan. OK. We're on a dead end street in the northwest corner of Grand Rapids, Michigan. So that's that's always part of my favorite part of the story here is we're kind of located on the edge to nothing. And despite all that, our folks here have made so many great changes over the years that we've had thousands of people from, I think, 26 states and eight countries that have come to visit us to see the systems that have been put into place over the years. And we're only a 40 person company. Twenty eight thousand square feet. So we're just a small about on the map that that over the years have made a big ripple in the pond. The precision machining industry. And it is exciting that we've got such a great group of folks that have not only made change, but we've made a lot of improvements over the years. But part of our story that we'll get into and will allow is we're making a lot of change, but we kind of lost sight of whether or not some of that was improvement. So we could see a lot of change around here. But the dials stopped moving after awhile. And so we had to go back to the drawing board. And that drawing board was Dr. Demings work.

Dan: [00:04:35] Okay, very good. Well, let's pick it up from there. So how did you guys come across Dr. Demings work? It sounds like maybe you initially knew Dr. Deming then kind of got away from it. So once you share a little bit about your journey there.

Brian: [00:04:52] So this, Brian, and back when I was a young 20 some year old, I happened to go to a statistics course, and during that course the instructor had mentioned Juran and Deming. So I began with Juran and in Juran Zone books, he mentioned Dr. Deming, so once I completed listening to the doctor, Mr. Grant, I read out of the crisis and.

Brian: [00:05:18] I don't know that it made complete sense to me at the time, but it did. The thing that got me was the study of variation. But so I spent five or six years diving kind of deep into statistics and I made some headway that wasn't I wasn't at Micron at that time. I was I was in the plastics industry. So when I joined my Mike Brown back in ninety one and.

Brian: [00:05:46] We were able to use some of the statistical tools so that in a way I was holding on to some old blood. Dr. Deming talked about variation. But I wasn't I wasn't truly knowledgeable about profound knowledge and the way to think of all of that. And then I admit to somehow I lost track of Dr. Deming for a decade or more. And then later, when Μicron started doing its deep transformation, Dr. Deming started coming to my mind more often. So I re-read the books again. And since then, it seems as though. There was a trajectory of adopting a little more of Dr. Deming, and then recently we seem to have found a new gear in regards to appreciating what he said.

Dan: [00:06:41] So a number of years ago, maybe the early 2000s. Brian and I have had a lot of conversations over our years of transformation. We always called it our lean journey. And that's that's how we knew it. But he would bring up regularly his views on variation. And then I asked, would you come up with all this? And we mentioned Dr. Deming and I need to learn more about this.

Dan: [00:07:07] Never, never really put forth the effort to do so. Until I was at a conference in Columbus, Ohio, I think about eight or nine years ago, and the speaker talked about the 14 points. It seems like I've heard of those in the past. Any you talk further about the doing performance evaluations and the disrespect that came from it. It just so happened to be the high end and pushing performance reviews here created a very in depth system. We're doing them quarterly. We're doing all this stuff and I hated every minute of it. And I couldn't put my finger on what was it that I felt that was wrong with it until I heard the speaker say just how disrespectful Dr. Deming felt that they were and why that day.

Dan: [00:07:58] I decided before I left that meeting, we were never doing another one. And I came back and I told our management team it's called team strategy. I apologize for pushing it so hard for so many years and shoved it down everybody's throat. And today we stop. I. I wish I would have gotten a picture of the room on that day, because I think the shock phase, after pushing it so hard that doing a complete 180, but it truly was like like seeing the sun come up because it put words to the feeling that was growing in me, that this is just wrong because half the people were walking out of the room feeling they were below average. Right. Who do you want to feel that way? And that was the day that I thought, I need to learn more about this guy.

Tripp: [00:08:46] Very interesting. So. So, yeah, go ahead.

Dan: [00:08:50] Oh, I'm sorry. So I was a few years after that that I don't and I can't recall right now how I caught wind of the Deming research conference in Fordham University in New York. And we've done a lot of presentations, like I mentioned earlier, sharing our lead story. And so I thought I'll submit and see us there is interested in her interest in hearing our story at the research conference. And then I was honored to be selected to do that. And.

Dan: [00:09:23] It was then that I met Dr. Demings, daughter and grandson, great grandson, and and heard everybody else that was speaking there, it truly became inspired by what I heard. And and Brian joined me on that trip and I brought my 15 year old daughter at the time and I thought because the story was about this whole story of Μicron. And I just wanted. I thought she needs to hear what grandpa and grandma created because I didn't mention earlier, I'm the son in law of the founders, but so I brought her with me.

Dan: [00:09:58] And it turns out she was the youngest attendee at a DME conference, I think, in the history of the den. And so Kevin and his wife is her name's Judy, I think, right? Yep. Yep. So they embraced her so much. I was really touched by that. So when the conference came to Michigan State University, where my daughter attends now at the conference, we walked in and she was just going to visit and say hi and whatever. And they made her so welcome. And got her a badge and invited her to attend a conference and everything. And it was really touching that they had a remembered her and they have really embraced a young person. And she's brought it up so many times. And and it's just that to me, that whole story just adds flavor to what I believe is the Deming community that I'm beginning to learn more about. So it's not just about the things he taught, but it's I'm beginning to see that the people that truly understand them are beginning to it. It's a group that we need to hang out with more. Right.

Tripp: [00:11:06] Very good..

Tripp: [00:11:07] So so let me ask you guys, when you started in to the Deming philosophy or as you've worked with with it, what things have you either personally struggle with or maybe even the organization has struggled with?

Dan: [00:11:23] So for me, I mentioned it again today in our strategy meeting to Brian and others that my 2019 transformation that came earlier this year when Dennis Sergent was the instructor of our Deming CQ Academy is what he calls it. And there was so much reference to improve it. So I love the statement. All premier requires change. Not all change results in improvement. So that was great to hear her have heard that before. But. I am a numbers guy. True and true on the facts and figures and dates and deadlines, you gotta go. You know, maybe that's part of being a plant manager. I don't know, but I begin to understand that.

Dan: [00:12:18] And then we've done a great job recently with our team strategy meetings. We are going to take a step in the right direction every day. And we we don't hold our feet to the fire like we used to about by this date. This thing has, you know, those kinds of things that the made up numbers of.

Dan: [00:12:35] You got to hit this goal by this day. We still have some of that. But there's far less focus on that than there was coming into 2019. And I struggle with it every day, every day that I bite my tongue and say, don't kick a no, don't create a no, don't push a number. Push the improvement and true change towards what we are looking to accomplish.

Dan: [00:13:01] And it's it's liberating, to say the very least. And again, it's humbling. It's almost like that day came back and say and said, when I do another performance evaluations offered me by longshot that because it's such a one idea who I am.

Tripp: [00:13:18] Interesting. Brian. Brian, how about you?

Brian: [00:13:22] Well, first, I want to attest to watching Dan's struggle with Martin.

Tripp: [00:13:28] Okay, so you've witnessed it. Okay, I got it. I think me.

Brian: [00:13:36] Oh, recently I encountered a. A customer had a problem, and normally if if we have material here that we asked to re-inspect, we learn how to do it. And we show another person how. And we call that a training system.

Brian: [00:13:53] And for some reason, and this particular incident, I decided instead of training the way I always have, I'm going to do it different. Because Mr. Deming said you should look harder at your training systems. There are likely problems there. And so I decided what would be a better way. And when I was done, it literally opened my mind to the amount of variation in a training system.

Brian: [00:14:22] Either doesn't pay attention to or creates all by itself, and so that would be a thing that recently happened to me in regards to understanding better, something that Mr. Deming talked about.

Tripp: [00:14:39] Very good. So here's a question for both of you. And it does matter what order that you respond. But if you were if you're a manufacturer, it's, say, listening to this podcast episode and you were thinking about this. What are some of the maybe, I don't know, pointers that you might give them about going to this philosophy, Will? What are the steps that you think they might go through or what advice might you have?

Dan: [00:15:10] That's a very good question. I think that as in most things, learning has to take place. And for me and for Brian, that fact he's got out of the crisis in his hands now, I've got some sticky notes in it.

Dan: [00:15:25] I get it. I always give Ryan a little ribbing because I call his Brian Dowling Bible here because he carries with him everywhere. I don't think I'd recognize him if he came to work about the thing in his hands. I think you have to start there. And I didn't start there. I just read the New Economics. In fact, I just got done with it in recent ago. First book I ever read.

Dan: [00:15:52] And then I have a long time ago, before I went to the Research Council that I read online, I learned more. I loved the history. I loved the fact that he grew up in a farming area and studied. How should it be? Because I grew up on of farm in Michigan here. So that really all resonated with me. And as I began to learn his story and his half life begins to patch together a lot of thoughts about how this may have all developed for him. And I want the history part of it. That's great. So I would suggest people be read about him and listen to these podcasts for sure.

Dan: [00:16:33] Look online if the educational beginning. But it was instrumental earlier this year. After all this time, haven't taken the Dennis Surgeons CGI Academy that really gave us this. It's what we did, guys. And I have to believe these types of sessions are all over the United States for people to be able to learn more and participate in groups. Exactly. And implement exactly what he's what he's trying to implement. And so through that, one of the things that's occurred to me this year is I began to have a greater recognition and appreciation for. Let's go back to our founders, Ed and Jackie Preston. You know, back in 1952, they they started this business.

Dan: [00:17:18] And so when I came on board in '96. There was a a few things that stood out to me. A phone never rang more than three times because it was disrespectful to the customer to make them have to listen to the ring on the phone more than three times. It was just a thing. Everybody here still knows by the time that there is a fourth ring, everybody in the plant is running for a form because it shouldn't ring more than three times. That system still by Mr President from the beginning.

Dan: [00:17:46] The other thing is when we have meetings here and we have a lot of meals at this company, the first an Ed or Jackie Ed's passed away now. And anytime we had a meal, they always eat last. They always insisted everybody else. You go first. We go laugh. Simon Sinek wrote a book. Leaders eat last. And when I read that, I saw Jackie. But I still believe it's all part of what Deming. His respect that he had for people. And and I saw so much of that and have seen so much in adding Jackie over the years that respect for people to make sure that the people in this company are taken care of first.

Dan: [00:18:30] And how so? So I would read, learn and then recognize and appreciate what already exists around you. And then I would start, I think, trying to implement the things that you were there.

Tripp: [00:18:43] Brian -do you have something to add.

Brian: [00:18:46] Not really know that.

Tripp: [00:18:50] No, that's fine. So let me ask you. Just kind of a broader question. I guess it looked like you guys sell globally, correct?

Dan: [00:19:00] Mostly in the United States. OK. If something goes outside of the United States and through our customers, not not directly from us to a customer outside the United States.

Tripp: [00:19:12] Ok. So has the environment changed much? I mean, there's a lot going on economically for your company. Is it gotten a lot better or is it kind of been stable all along or what's it like out there as far as manufacturing goes?

Dan: [00:19:28] So this year there's been a softening in general across pretty much all of the industries that we serve.

Dan: [00:19:37] And we we serve a number of them. Most of our business is relatively local. About 70 to 73 percent is in Michigan and the rest is either in southern Indiana or Texas. Shooting down that quarter in general have softened. And I just saw the numbers today that manufacturing in the third quarter actually went up a touch, which surprised me because we haven't seen it and I haven't heard that from our suppliers, to be quite honest with you. But one of the things that we've tried to do over the years, as we called our lean journey or on our shifting gears and to we actually trademarked a year or two ago the term system, Micron, because the reason people come here, the reason three thousand people visited are to see our systems. We had fire departments, health care, the company that created the resistor. And A we've had people from all over the world come to see how we schedule production.

Dan: [00:20:39] We have no mid-level management, how we have total flex time. People can decide which days they work, what hours they work. The whole nine yards. And and so people have come from all over to see how well how can we manage a company to where there are no bosses. There's a movie that tells people what to do. Brian, are the managers of quality in manufacturing and there's there's an engineering manager. We're responsible for the systems and making sure the people, the resources are there, of course. But it's it's really there's so much autonomy that people have. And and this year, really, over the last three or four years that we've been using the Toyota car, it really began to teach us a better understanding of the kind of calls PDCA.

Dan: [00:21:31] And that PDSA. So we use that language mostly because of that. But because of that, we began to emphasize every conversation. What did we learn? What did we learn? I think if I were to look back in the three last three years, the number one question that we ask yourself is what did we learn? Fill in the blank on whatever the heck it is that we're talking about. So I would I would dare say that the Deming philosophy is all about what have you learned? And we've embraced that.

Tripp: [00:22:04] And you guys have mentioned the lean journey that you kind of started on before you kind of got into Deming. What do you see as kind of the differences between them or or how did they maybe synergistically and engage with each other as you work through this or or what's happened with this this lean journey still continuing that as the Deming philosophy, enhance it. What's your view?

Dan: [00:22:34] So. I think that. Like most things in life, it's the perspective you choose. And I think that you can and perhaps many companies have chosen the perspective of Lean as the elimination of waste. And of course, that's an element of it.

Dan: [00:23:00] But I believe and we've used that language here a lot, but I believe truly that what we've tried to do with our lean journey is to best use our resources. So Dr. Deming talks about optimization of processes, right? We haven't used that language exactly a lot, but that's what our journey has been about. How do we optimize what we do? How do we create standards, stick to improve the standard and make things the lives of our people better?

Dan: [00:23:28] And that from day one, when we are first meeting about why are we going to take this lean journey? Way back in August of 2000, our management team said it is for one reason and that it is to make the lives of our people better and.

Dan: [00:23:46] From that day on, I felt as long as we have that focus. We're on the right path. And and so as we went through our lean journey, we were. Awarded the Shingo Silver Medallion for operational excellence back in 2008 93. And it's referred to as the Nobel Prize of Business or Manufacturing by Business Week. And that was nice to get. It was kind of a confirmation that we're on a good path, but the best thing about us told us all things we could do better. And so we tried to embrace them. And so on. As we learned more about the teachings of Dr. Deming, here's a thing that we weren't using properly our entire lean during that we're only now starting to learn and use much better.

Dan: [00:24:39] And that is the understanding of variation that Brian mentioned earlier or in control charts and we hadn't used. I don't know if we used a control Chart. Fifteen years probably that are 20 0 0 0. And now we really are. We're embracing the heck out of that. And we're beginning to understand where we have to measure data and where you continue on.

Dan: [00:25:02] Probably the greatest weakness, though, for us, the difference between how we treated women and what we're learning from Dr. Deming, though, is we are making a lot of change and we're necessarily tracking whether or not that change was an improvement towards the saying we needed improvement on. Right. Yeah. In that corner of the planet might look better now, but is it truly improving anything that's going to help the customer? And we lost sight of that for a while, I believe. And I think we're getting on back, Brian, to everything else then was pretty good a.

Brian: [00:25:37] The appreciation of a system as as we did the room. I think we learned more about systems because you have to diagram them out and understand the interactions between them. And so that kind of opened our eyes and just happened to fit in with a kind of reconfirms that Dr. Deming needs says. You should understand your system as good as you can. I think it also psychology. You know, in the beginning there are resistors because change is scary. And I'm sure some people wonder if you truly mean it. Or is that just the passing thing this month? And so you understand as you push that journey through and you get the buy in from people that that were once resistors. OK, that's cool. You get to watch and growth in your own people. You learn how to achieve that growth faster. Either by learning from your mistakes or the occasional times we we somehow did it right. So I thought all of that. There is a consistency between Lean and Dr. Deming. I think I can see that.

Tripp: [00:26:50] Okay. And Brian, you have to ask, because you mentioned that you kind of got into variation, you know, years ago or maybe even a couple of decades ago. And we're using it, you know, in what's different today, what it what it sounds like. You started into it kind of got away from it and then went back to it. What would take me a little bit on that journey?

Brian: [00:27:13] Long ago when I was when I first was introduced to it, we were trying to everything classic's and we wanted to learn how to build Dai's better. So is there a way to design a dye with more success by the time you're done, by the time you're finished? And I couldn't believe how much statistics help you in design. So that was kind of low hanging fruit and. So it's fun to play with.

Brian: [00:27:43] But we didn't necessarily use it in day to day production at that facility I worked with.

Tripp: [00:27:49] OK,.

Brian: [00:27:50] So then I. I moved on to Micron and that was my first attempt. OK. We don't use it to design our process, but we do use it to monitor our process. And back then, it was sort of driven by customers. They were requiring statistical data. And that's fine. But what's more, fighing are more fun to actually learn that you can predict your process. But I find that fascinating every day.

Brian: [00:28:19] So we're into that pretty deep for about four or five years. And for some reason, the customers decided to let those requirements go. And somehow that that seemed to be it took the wind out of the sails of that process.

Brian: [00:28:37] And so for some time, we didn't use statistics for quite some time. And then I would say in the last five or six years. We are doing more and more statistical studies and realizing once again the benefits of doing so. And now we're actually applying it to management processes rather than just parts or machines. And we're finding that. That is even more fascinating than than going out new in capability studies out next to a fancy.

Dan: [00:29:10] I think though, one of the stark differences between then and now is we did it because the customer demanded it and the sooner they stop demanding it, we stop doing it tells you how mature where I am right now.

Dan: [00:29:27] Now we go this beginning. We realize, as Brian said, it's helping us understand our management systems in ways we never would have dreamt before. And we're doing it because it's the right thing to do and you're learning from it. And we're the kind of company that there's no doubt in my mind that sometime very nearly down the road, we're going to be pushing this to our customers to try to do the same thing as we did that with our lean systems. When when we first started Dileep Journey by time 2003 rolled around, we had made a lot of changes and we realized that one of our customers had any idea what lean was. And we we began to bump up into. We can only improve our systems so well if we can't tie it to where our customers are demanding or needing from us. So we went on this magical mystery tour out to our customers for three years to try to see how can we link what we're doing to what you might need. And pretty soon, all of our customers want to delinked their systems to ours. And we went from like 16 percent of what we built was on some kind of pulse system to 68 percent within those three years. And it was an amazing thing because when they began to recognize what it could do for them and it helped us help them, it was great. So we were still and we began then to take what we've learned and what we knew and share it with the customer. So here's just another thing that as we learn more, I can see that we're going to share it with the customers because it will help them help us.

Tripp: [00:31:07] Very cool. So my last question for you guys is, is my typical one, which is. Is there anything that we've talked about or that you've responded to that you'd like to make a clarification of? Or is there any question I didn't ask that you wish I would have?

Dan: [00:31:28] That's really that's a great question.

Dan: [00:31:33] I know that they're the Deming Institute is reaching out to educational organizations across the country. I'm not aware of any of that in Michigan. There are individuals, like I mentioned Dennis a few times now that is trying to help industry. But it's important that we believe that the school systems are help. Few years ago, Mike Rather, the author of The Toyota Kata, was gracious enough to stop that. Mike Brown wandered through the plant. And then I was so bold as to invite him to teach the school that my kids went to grade school or how to do the participate in the Kata, which of course, as I mentioned, includes the whole PDCA cycle of improvements. And he did so and I thought it was a fantastic session. And it began the thinking, how can we get more AUTHERS? How can we get more people helping teach the schools that teach students how to be more critical thinkers? So I think that that would be something of. All certain interests of manufacturers all over the country. Here, as we try to help, you know, he knows the skills gap all the time, right?

Dan: [00:32:53] Mostly is a critical thinking gap in our opinion. We can teach the skill. So anything like that. We would love to see and hear more about it as time goes by.

Tripp: [00:33:03] Very cool, Brian. Thoughts? Last thoughts.

Brian: [00:33:07] Yeah, I don't remember who you were talking to and one of your podcasts, but your guest. You ask the question of them and I'm going to paraphrase. Do you think the Deming Philosophy is growing or shrinking or remaining the same. And he said he did not believe it to be growing.

Brian: [00:33:29] My guess, I was disappointed. Whoever your guest was, it seemed like a person that would probably know that answer better than I did. And that made me sad to think. And so I am curious, as Dan just said, you know, not only getting to the local school systems, but also the business schools. What is what is coming out of the business schools now? The people that we're going to hire soon?

Brian: [00:33:56] And then how do we get even further ahead, as Dan said? And get this all the way down to how do you teach young people to think in a better way? And.

Dan: [00:34:08] It's important for us. So earlier this year, Ryan and I both referred to CQI Academy that we had taken to learn more about Dr. Demings work, and I had coordinated through an organization called Discover Manufacturing here in West Michigan.

Dan: [00:34:26] They coordinated and I see it an industry led collaborative where four of our companies, 19 different people or 20, went to this class and one was in carbon composites, another one furniture, and there another machining company like ours.

Dan: [00:34:45] And it didn't matter that we were basically different industries and different walks of life. It was somebody from shipping to, you know, my position, brines as managers and everything in between. And it was a fantastic way to learn these collaboratives of different companies. So we're intending to do it again this next spring. I'm signed up as the co-lead for Discovery Manufacturing and make sure you do. And that's that's our contribution to try to make sure that we're spreading the teachings of Dr. Demings in West Michigan here, because regardless, I'm not sure what else we can do other than it here. We have tours every two or three weeks and people who come see it and we're trying to help this. I'll see more companies learn about it. So I hope that your listeners and companies that are getting involved open the doors and bring people in and show what they're learning. It doesn't matter how minor it is. Teach what you're learning and then try to get other companies together to do the same.

Tripp: [00:35:53] And that's sage advice. We appreciate it. Well, Dan and Bryan, we certainly appreciate you being part of the Deming Institute podcast.

Dan: [00:36:04] Well, thank you, Tripp. Greatly appreciate it.

Tripp: [00:36:08] Thank you for listening to the Deming Institute podcast. Stay updated on the latest blogs, podcasts, programs and other activities at Deming dot org.

In our 29th "Deming Lens" episode, host Tripp Babbitt shares his interpretation of wide-ranging aspects and implications of Dr. Deming's theory of management.

[00:00:15]
Deming Lens - Episode 29

[00:00:32]
Point 14 - Take Action to Accomplish the Transformation

[00:02:23]
Two Takeaways - Top Management Leading the Transformation and Critical Mass

[00:03:55]
Top Management vs Individual Transformation

[00:05:14]
Critical Mass

[00:08:40]
Dr. Ed Baker - The Symphony of Profound Knowledge

[00:11:17]
Doug Hall - Innovation

Tripp: [00:00:15] In the twenty ninth episode of the Deming Lens, we go through the last of Dr. Demings 14 points. Point 14, take action to accomplish the transformation.

Tripp: [00:00:32] Hi, I'm Tripp Babbitt, host of the Deming Institute podcast, and I took a bit of a hiatus from Demings 14 points for a while because when I was researching all 14 points probably close to a year ago before I even started this Deming lens, focus on the 14 points of Dr. Deming. I really got sidetracked on what I believe Dr. Demings challenge to people using his philosophy, whether that's people within the Dumain community or from without the Deming community. And it actually helped me to launch a podcast that I'll talk about later because of point 14, which is accomplished the transformation. And I have some thoughts about that and some things that maybe we can all do moving forward. But as usual, I'd like to start with Dr. Deming talking about point 14,.

Dr. Deming: [00:01:43] Number 14. Let's get about it. How do you go about top management? I think we reconstituted that movement will have to come from top management. You must create a critical mass in the company that understands the job of top management is. Otherwise, they cannot do the work. There's critical mass. How do you go about seminars, teaching, providing fit material, classes? Anything. Do it.

Tripp: [00:02:23] Now, there's a few things that Dr. Deming actually two things that Dr. Deming talked about in this segment that we just listened to. He talked about top management and he talked about critical mass. And when you look at top management as the focus to make the transformation that seems to come into conflict with some of the things that the director of the Deming Institute, Dr. Demings grandson, Kevin Cahill, talks in terms of that you have to transform the individual. Now, how can you focus on top management versus the individual? Well, you have to start with somebody in a position within the organization. And top management in order to really begin the transformation. But the transformation does begin with that individual, someone, you know, within the existing hierarchy, because they haven't been enlightened by the Deming philosophy. So there has to be someone that sees some worth within the organization. Now, I'm not going to say that it's just top management, cause certainly I have seen and I am of the belief that you can start from other parts of the organization to begin to get the second item. Other than top management, which is a critical mass.

Tripp: [00:03:55] But going back to this kind of top management versus individual transformation in order to get resources, typically you're going to need to get top management involved to do you know whether it's education or console consulting or just allowing time resources to be able to work on the philosophy itself will involve someone that can.

Tripp: [00:04:22] Give you resources within an organization to do so. Now, that doesn't mean you can't do something on your own. I certainly started that way by reading Dr. Demings books and things of that sort. But it certainly is helpful to have someone in an executive position or a position of influence. Maybe you would be a better word to help get things kicked off. So I don't see Dr. Demings focus on top management and Kevin Cahill's talking about. You have to begin with the transformation by individual. Those two things, I believe, are. They work together. It's part of a part of the system. Now, let's talk about the critical mass.

Tripp: [00:05:14] The second component, which is something that I I had read many times and out of the crisis and the new economics and things of that sort. It wasn't till a conversation with David Langford that I started looking at this critical mass. And David Langford told me that Dr. Deming shared with him when he asked him about, you know, what is the what is a critical mass within an organization? And that Dr. Deming said that it was the square root of the number of people in the organization. So a critical mass for a hundred person organization would be 10 people.

Tripp: [00:05:54] And I thought, OK, so what in essence he's saying is if you can get a critical mass of people within the organization thinking in the ways of the Deming philosophy, then you can begin to make the transformation. And David Langford was a teacher, so he wasn't an administrator of the school, but he was able to get the the resources because he made a compelling argument associated with transforming, transforming a school in the Deming philosophy in Sitka, Alaska, because of.

Tripp: [00:06:35] His ability to work with Dr. Deming and then apply those principles to beginning that transformation. So it is possible. And I again, I've worked with organizations where I've started with people that were more middle management and beginning to see things differently and using different tools that got the interest of executives.

Tripp: [00:07:02] And then we start to pull them in. So there are ways to make the transformation happen. And to begin to get a critical mass of people.

Tripp: [00:07:12] Now, I always focus on people that are open to the message. So if there's someone within an organization that calls me up and they'll say, I'd like to get started in this, then I will give them a series of things to read. We'll have a few conversations and they can begin to not only transform themselves, but then they can also begin to transform other people by sharing what it is that they're learning. And I give them a variety of things to do. And I've done this for many years now, kind of a almost a personal coaching.

Tripp: [00:07:46] So there is a way to transform yourself nowhere where no matter where you sit within an organization with the aim of getting a new perspective, a new way of thinking within the organization, starting with yourself. So this is going to be part of the Deming Institute's focus is how do we transform the individual? Now, here is something that I think is the challenge.

Tripp: [00:08:21] If you go back to the interview I did with Ed Baker, he was asked by Dr. Deming or had a conversation with Dr. Deming, where Dr. Deming said to to Ed Baker that he needed to write a book because he had a different perspective than Dr. Deming had different education.

Tripp: [00:08:40] There are a lot of things that Ed Baker had that Dr. Deming said because of these things, because you have a different perspective that, you know, I'd like to see you write a book. Now, if he didn't do it properly for 30 years later. But but he wrote he you know, he wrote a very good book called The Symphony of Profound Knowledge. So here's the kicker. Basically, as I was going back through Dr. Demings 14 points, it came to mind to me that Dr. Deming was looking for a variety of perspectives on communicating the DMA, the Deming philosophy. Now, none of them are Korac. None of us are Dr. Deming. Some of us have studied Dr. Deming for a long period of time, especially within the Deming community. But we all have a perspective and we all have something to offer in the way of either a model or a blog, podcast or whatever. And so this is one of the reasons that I launched a podcast called Mind Your Noodles. So where I'm taking neuroscience and some of the findings in neuroscience that actually seem to be supporting a lot of what Dr. Demings message was and his philosophy and begin to build a model based on the Deming philosophy. Now, I'm not the only one out there doing this, but I think there ought to be more. I think Dr. Demings philosophy and if you listen to some of the things that he said, it was almost a challenge to all of us that were followers to what was to come up with a way to accomplish the transformation. Now, be the first one to say, I know he would quote, I believe from George Box that there is no perfect model. Some are useful. So we can have to take that. But I I believe there's more to be offered by people doing things to promote the philosophy, not necessarily as the forefront, but as a underlying base to the lot of the things that we're doing. So my attempt was coming up with a podcast and beginning to build, in essence, a model based on the dumbing philosophy. Now, others have done this.

Tripp: [00:11:17] There's Doug Hall, who does and uses the Deming philosophy in his innovation methods. So he's come up with a method for a system for doing. Innovation based in the Deming philosophy, is it flawed? Yeah.

Tripp: [00:11:40] So it was mine, by the way. And is it constantly being scrutinized and upgraded and updated and refined and all of that? Yes, because he has gone through middie iterations as I'm going through as I build my model.

Tripp: [00:11:59] And actually Doug's innovation piece fits into the model that I'm building. So, yeah, we've got this people. We have people out there that have ideas about how to do the Deming philosophy and we can can continue to learn. But I'd like the idea of learning from doing by virtue of a blog. By virtue of our podcast. Speaking of whatever it might be, where you can continue to refine your message as well as get the message out to people.

Tripp: [00:12:40] So my challenge to people that are interested in the dubbing philosophy. People from within the community is to do those things.

Tripp: [00:12:49] Go out and write a start a blog, do a podcast. You'll build a platform, a stage where the Deming philosophy can be communicated moving forward and refine it. Dr. Deming was the first one, in essence to say, you know, I make no apologies for learning and I think advancing the thinking associated with the Deming philosophy. For those of you who think that the Deming philosophy is the static thing, it can't be because Dr. Deming was hardly static. It's constantly adjusting his theories. He was constantly adjusting his philosophy from what he he saw. And things have changed. And I think that in order to keep up with the changes that are happening, we've got to find new platforms, new stages, books, podcasts, whatever it might be to be able to communicate the Deming philosophy in a way that we can continue the learning. So that's the last of the 14 points and my thoughts about some of the things, though, that I believe as a community we need to do moving forward to continue to refine it.

Tripp: [00:14:08] Thank you for listening to the Deming Institute podcast. Stay updated on the latest blogs, podcasts, programs and other activities at Deming dot org.

In our 28th "Deming Lens" episode, host Tripp Babbitt shares his interpretation of wide-ranging aspects and implications of Dr. Deming's theory of management.

Topics in this episode include:

• The 13th of Dr. Deming’s 14 Points –Institute a vigorous program of education and self-improvement.
• Dr. Deming – “keep elevating people’s minds”
• Dr. Deming - “education need not be connected with their [employee's] work….keep people’s minds moving”
• Are we missing opportunities to have employees engaged their brain in something bigger than themselves?
• What is the role of the ventral striatum on being curious?
• Getting new ideas from diversity – gain diversity in many ways
• Personal impact of attending a Four-Day Seminar with Dr. Deming
• Tripp’s pivot points once discovering the Deming Philosophy
• The impact of the design of a given system
• Living up to Dr. Deming’s principles
• Is learning your lifetime goal?
• Dr. Deming, “I make no apologies for learning”
• Reading more than “Deming” material 

Dr. Deming's 14 Points are fully covered in Out of the Crisis. The New Economics presented his later thinking about the 14 points. 

In our 5th interview podcast of 2019, Alan Winlow, MBE, former Managing Director of Yorkshire Brick Company, Continuous Improvement Director at Marshalls PLC, and 2019 ASQ Deming Medal Recipient, offers insights on his efforts to lead a Deming transformation.

(This is Tripp's first interview with Alan)

Highlights include:

• Opening quote from Myron Tribus, "If you continue to do what you've always done, you will continue to get what you've always got"
• In the late 1980s, while serving as Managing Director of the Yorkshire Brick Company (YBC), employment in the UK brick industry plunged from 14K to 8K employees and plants were closing
• Question at hand, "How to survive in a labor-intensive business?"
• How had the Japanese captured critical UK business segments?
• Started to read about Dr. Deming and attend British Deming Association conferences
• Discovered sources of variation and PDSA, plus the importance of data
• Found the majority of variation came from manufacturing equipment and raw materials for the bricks
• Discovered how to change the brick manufacturing process to improve brick uniformity
• Began to meet regularly with YBC's production team to continue to improve brick uniformity, savings in water use, energy use, and discarded bricks
• Discovered mental models, including the Taguchi Loss Function
• Explored how to remove barriers within workforce, everyone came on staff
• Began to understand what his job was, including reading books and seeking new learning
• Alan led consulting visits to China in 1987 to assist in developing the Land Fill Gas business. The Chinese were extremely interested in the landfill gas abstraction at YBC and sent no less than 8 delegations to visit the Yorkshire site. Alan was invited to visit by the Mayor of the city of Anshan.
• Teaming with local schools and universities, a local jail, and a county council to share lessons learned within YBC, including environmental projects
• Yorkshire Brick was honored in 1991 for contributions to environmental causes
• In 2000, Alan was honored by Queen Elizabeth as a Member of the British Empire for his leadership within YBC
• Never met Dr. Deming at BDA events; met Myron Tribus on many occasions
• Comments on challenges in implementing the Deming Philosophy
• Continued relevance of the Deming Philosophy today

In our 5th interview podcast of 2019, Alan Winlow, MBE, former Managing Director of Yorkshire Brick Company, Continuous Improvement Director at Marshalls PLC, and 2019 ASQ Deming Medal Recipient, offers insights on his efforts to lead a Deming transformation.

(This is Tripp's first interview with Alan)

Highlights include:

• Opening quote from Myron Tribus, “If you continue to do what you’ve always done, you will continue to get what you’ve always got”
• In the late 1980s, while serving as Managing Director of the Yorkshire Brick Company (YBC), employment in the UK brick industry plunged from 14K to 8K employees and plants were closing
• Question at hand, "How to survive in a labor-intensive business?"
• How had the Japanese captured critical UK business segments?
• Started to read about Dr. Deming and attend British Deming Association conferences
• Discovered sources of variation and PDSA, plus the importance of data
• Found the majority of variation came from manufacturing equipment and raw materials for the bricks
• Discovered how to change the brick manufacturing process to improve brick uniformity
• Began to meet regularly with YBC's production team to continue to improve brick uniformity, savings in water use, energy use, and discarded bricks
• Discovered mental models, including the Taguchi Loss Function
• Explored how to remove barriers within workforce, everyone came on staff
• Began to understand what his job was, including reading books and seeking new learning
• Alan led consulting visits to China in 1987 to assist in developing the Land Fill Gas business.  The Chinese were extremely interested in the landfill gas abstraction at YBC and sent no less than 8 delegations to visit the Yorkshire site. Alan was invited to visit by the Mayor of the city of Anshan.
• Teaming with local schools and universities, a local jail, and a county council to share lessons learned within YBC, including environmental projects
• Yorkshire Brick was honored in 1991 for contributions to environmental causes
• In 2000, Alan was honored by Queen Elizabeth as a Member of the British Empire for his leadership within YBC
• Never met Dr. Deming at BDA events; met Myron Tribus on many occasions
• Comments on challenges in implementing the Deming Philosophy
• Continued relevance of the Deming Philosophy today  

In our 5th interview podcast of 2019, Alan Winlow, MBE, former Managing Director of Yorkshire Brick Company, Continuous Improvement Director at Marshalls PLC, and 2019 ASQ Deming Medal Recipient, offers insights on his efforts to lead a Deming transformation.

(This is Tripp's first interview with Alan)

Highlights include:

• Opening quote from Myron Tribus, “If you continue to do what you’ve always done, you will continue to get what you’ve always got”
• In the late 1980s, while serving as Managing Director of the Yorkshire Brick Company (YBC), employment in the UK brick industry plunged from 14K to 8K employees and plants were closing
• Question at hand, "How to survive in a labor-intensive business?"
• How had the Japanese captured critical UK business segments?
• Started to read about Dr. Deming and attend British Deming Association conferences
• Discovered sources of variation and PDSA, plus the importance of data
• Found the majority of variation came from manufacturing equipment and raw materials for the bricks
• Discovered how to change the brick manufacturing process to improve brick uniformity
• Began to meet regularly with YBC's production team to continue to improve brick uniformity, savings in water use, energy use, and discarded bricks
• Discovered mental models, including the Taguchi Loss Function
• Explored how to remove barriers within workforce, everyone came on staff
• Began to understand what his job was, including reading books and seeking new learning
• Alan led consulting visits to China in 1987 to assist in developing the Land Fill Gas business.  The Chinese were extremely interested in the landfill gas abstraction at YBC and sent no less than 8 delegations to visit the Yorkshire site. Alan was invited to visit by the Mayor of the city of Anshan.
• Teaming with local schools and universities, a local jail, and a county council to share lessons learned within YBC, including environmental projects
• Yorkshire Brick was honored in 1991 for contributions to environmental causes
• In 2000, Alan was honored by Queen Elizabeth as a Member of the British Empire for his leadership within YBC
• Never met Dr. Deming at BDA events; met Myron Tribus on many occasions
• Comments on challenges in implementing the Deming Philosophy
• Continued relevance of the Deming Philosophy today  

In our 27th "Deming Lens" episode, host Tripp Babbitt shares his interpretation of wide-ranging aspects and implications of Dr. Deming's theory of management.

Topics in this episode include:

• The 12th of Dr. Deming’s 14 Points – Remove barriers that rob people in management and in engineering of their right to pride of workmanship.  

• Absenteeism due to lack of pride in work 

• Handicaps to productivity, quality, and competitive position 

• Workers treated as a commodity; Human Resource Departments

• Hire people, as needed; discard them, when not needed 

• Layoffs after cutting dividends, reduce salaries of top management, cutting bonuses, furloughs, etc.

• Handicaps when Management is helpless when working with people, including unable to receive feedback

• Performance appraisals will need to be supplanted by leadership in helping people

• Solutions which “improve” performance appraisals, vs not utilizing them 

• Managers using reports and data and not collaborating with their staff to look past the reports and data

• Signs of a lack of pride in workmanship, all systemic – turnover, stress levels, health issues, sense of indifference

   

Dr. Deming's 14 Points are fully covered in Out of the Crisis. The New Economics presented his later thinking about the 14 points.