During a recent business trip to Mexico, I spied a hotel worker using the tools captured in the picture. While there is definitely some creativity applied in the development of the tools, the twig broom (or is that a rake?) clearly is not sufficient – lots of motion required, but much of it wasted.
This same thing happens way too often in other gemba locations. Insufficient tools, and often just the plain LACK of tools, get in the way of performance.
The four-fold improvement objective is first, easier, then better, faster, and cheaper. Short-sighted leaders often think they can jump to cheaper by being cheapskates when it comes to basic tools for the job. Among other things, this belies a lack of respect for the employee. Maybe they need to “walk a mile” in their employees’ shoes...or at least directly observe reality at the gemba!?
Just to be clear, here we’re talking about pragmatic tools, not overbuilt, gold-plated tools with unnecessary features and performance levels. And yes, as the saying goes, we must always, “reach for our brain, before our wallets.” But, workers need sufficient tools that: 1) protect them from ergonomic stress and trauma, 2) are capable of producing sufficient repeatable outcomes, and 3) support the least waste way, as captured within good standard work.
I’ve run into my share of “bad brooms,” as in the picture. Like the homemade knives that the operators made in order to cut foam. Their knives were basically pieces of scrap metal, with tape wrapped around one end for the handle. No knife looked the same. Many made ragged cuts. A lot were unsafe. Could management have done a better job?
How about the leaders who resist buying the required hand tools and storing them, at the behest of engaged employees, at a point-of-use shadow board for a routine set-up? The tools will get lost or stolen, anyway, why bother? Meanwhile, operators constantly venture out on long, time-consuming safaris to go find the required tools (yes, I know tool-less set-ups are the target condition…). Not easier, and certainly not least way.
We could go on. I am sure that you have countless examples from your gemba.
The scary thing is that workers in such situations get numb to the waste that their cheapskate leaders have helped create and sustain. Penny-wise, pound foolish environments are death to the kaizen spirit.
Don’t be a cheapskate.