Archive for category: Sara Hanks

Embracing the Elements: My Icelandic Adventure

Guest writer Sara Hanks brings us the lessons she learned through vacation in “Embracing the Elements: My Icelandic Adventure.”

As I was unpacking after returning from my journey to Iceland, a quote on the hiking shoe box caught my eye, “It can be easy to forget how much beauty surrounds us, but <Insert Shoe Company> gets you to a place where you can enjoy the world around you.” The words struck a chord, as a beautiful summary of my experience and reflection of the lessons I had learned throughout the vacation.

Be Prepared

The first key takeaway was to Be Prepared. The 10-day forecast on the weather app on my phone, would not have prepared me for the elements we encountered. Several days were met with heavy winds and rains. At one point, the road closed due to high winds. When the road opened and we could drive through, there were several vans and trucks destroyed from being blown off the road. I’m grateful that my sister is always cold and warned me to pack with the worst weather in mind. The treacherous winds and heavy rains were no match for my waterproof hiking shoes, rain pants and layers of jackets. I enjoyed each moment because I was prepared.

Be Silly and Have Fun.

Be Silly and Have Fun, was a lesson I encountered in surprising ways. From running to see what treasures hid around the bend in the trail to being up close and personal to farm animals, I found pure joy. Trying to keep my balance in the wind, watching sheep being born, and petting the friendly Icelandic cows brought out a childlike sense of wonder and giggles. One cow decided to put my foot into its mouth. The small, whimsical moments made me realize the satisfaction of embracing the unexpected and amusing things in life.

Be Present in the Moment

Nothing taught me to Be Present in the Moment better than my hike up the stairs to the top of Skogafoss. With each step up the steep staircase, I was fully engrossed in the task at hand… get to the top, safely. When I reached the top, the view was amazing, as were the winds. Traveling back down the stairs was one of the most terrifying experiences of the vacation. Railings only existed on one side of the staircase, and they switched sides randomly. I found myself competing with the people climbing the stairs, especially when the wind gusts were greater than 30 MPH. All thoughts of work, LinkedIn notifications, and the incomplete chores were non-existent.

Get Outside

The lesson to Get Outside was driven home by a multitude of experiences. From riding an Icelandic horse to the stone beach, to boating around bright blue icebergs, each moment spent outdoors was a refreshing escape from the digital confines of everyday life. Oddly enough, I felt no knee pain during this vacation; I could run pain-free for the first time in years. I believe the constant movement in the fresh air was a big contributor. Now that I have all-weather gear, there is no excuse to avoid being outside.

Prioritize What You Love to Do.

Lastly, this trip reminded me to Prioritize What You Love to Do. I’m flexible and adaptable, so going along with others to do whatever, is not a problem. In Iceland, I rediscovered my love for adventure in the outdoors. Seeing geysers, making snow angels at the base of snow-covered mountains, hiking through a farm to a secluded waterfall, and being chased by a herd of Reindeer brought complete joy. It was a strong reminder that investing time in my passions brings both pleasure and a sense of fulfilment. 

The quote on my shoebox perfectly described my Icelandic journey. Amidst the wild landscapes and memorable experiences, I had not just traveled across a country, but traveled on a journey of self-discovery. The joy, serenity, and renewal I found in Iceland shall be continued through these lessons.

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Mastering Nonconforming Material Management for a Leaner, Meaner Business

Guest writer Sara Hanks offers practical tips on mastering nonconforming material management for a leader, meaner (but nicely!) business.

It is great to be back with another blog post. While the title might suggest that I’m advocating for a “meaner” business, I’m not encouraging cutthroat tactics. Instead, let’s explore how to master nonconforming material management and make your operation leaner and more efficient. 

As an operations or quality leader, improving the nonconforming material management process is essential to reduce waste, enhance efficiency, and prevent recurring defects. We’ll delve into three practical steps to accomplish these goals and showcase an example from my personal work experience. Managing the nonconforming material process in a timely manner will avoid costly consequences.

Segregate and review defective parts daily.

Start with establishing a visible area to segregate the defective parts, as this will prevent the defective parts from being used in production or in your service center. Review the parts in the segregated area on a regular basis. Daily reviews are ideal to keep the parts top of mind. 

While I was the quality engineer of an electric motor manufacturing company, there was an issue where a part failed due to an electrical issue during the final test. The motor was set aside to make room for production. A day or so later, another similar issue occurred, and a day or so after that an electrical issue occurred with a component that went into the motor. Eventually, we discovered the root cause of the issue – the wire that made the electrical parts that went into the motor had a defect. The defect could pass several tests and go undetected; piles of parts have accumulated. If we reviewed the issue regularly, the root cause would have been discovered sooner, saving a lot of rework costs.

Define ownership and measure cycle time.

There are four major steps to a nonconforming material management process: identify/segregate, disposition the fix, execute the disposition, and verify the completion. Each phase needs an owner. In the execution phase, different teams own the step based on the disposition. For example, scrapped parts or parts that need to be returned to the supplier are managed by materials, whereas parts that require rework should be managed by operations. 

Once it is clear who owns which step, measure each step of the process. If the process is managed in an IT system, there are date stamps recorded as parts move through the process. These can be used to create the measurement system. Set goals for each step. If you are not sure what goal to set, try a 10% improvement over an established baseline, which can be determined by measuring the data for 8-12 weeks.

With the electric motor issue, the lack of ownership of each step extended the time to resolve the issue. The purchasing team was responsible to send the motor out to be torn down, however, the parts did not ship for several weeks after the root cause was identified because they weren’t held accountable. The accumulated defective parts sat in inventory – remember these are nearly finished goods, not supplied parts, so the inventory impact was significant. Additionally, the customer order was finite. We left the repairs to the last minute and used overtime to ship the parts on time. Measuring the process by the owner would have prevented the unnecessary cost.

Implement a Continuous Improvement Framework

My favorite continuous improvement framework is the DMAIC process, or Define, Measure, Analyze, Improve, and Control. However, when it comes to continuous improvement for everyone in the organization, the DMAIC process may be too challenging to learn and adopt. A simpler, more accessible framework is the Plan-Do-Check-Act or PDCA framework. Here is a brief overview of the PDCA cycle: 

• Plan – identify a problem that needs solving or an opportunity for improvement. Analyze what can be done, establish a goal and identify the steps needed to accomplish the work.
• Do – implement the plan, on a small scale if possible.
• Check – evaluate the results.
• Act – Standardize effective solutions or iterate back through the cycle.

Encourage everyone to participate in PDCA projects. Create a reward system to promote engagement. Rewards can be simple, such as recognition during an all-company meeting, or celebrating with a small party. Company swag is good, especially if employees can wear it during work hours. Buying a jacket or a hat for completing a project is extremely low cost compared to the savings of the project. This approach helps in addressing the root cause of defective parts, which will impact the cost of quality over time.

In the electric motor example, we did identify a corrective action project to prevent a recurrence. In the wire manufacturing process, a preventive maintenance schedule was created to replace components likely to wear on a regular basis. The small cost of changing a roller is minute compared to the larger expense of reworking the finished product. I cannot remember if we celebrated with a pizza party or not, but in hindsight, if we didn’t, we should have!

Take inspiration from my electric motor example, where timely root cause analysis could have saved money and contained the issue. Don’t let nonconforming materials pile up and obscure underlying problems. Instead, tackle them head-on with proactive measures that involve the ENTIRE team. By doing so, you can avoid missed deliveries due to quality issues and foster a culture of continuous improvement.

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Making It Happen from the Middle

Guest writer Sara Hanks talks about how to continue to make changes without a top-down ability in “Making It Happen from the Middle.”

For nearly a decade, the digital transformation projects, and teams that I led were funded from corporate. Although there were aggressive cost-out targets that came along with the program budget, it was clear that the initiatives were selected at the top of the organization and disseminated down. When the team encountered resistance to change, an escalation a couple layers up settled the dispute quickly. The blunt object from the top paved paths that would otherwise be a challenge.

In February 2019, our division was sold to another company. Their IT strategy was not the result of a CEO initiative and the concept of functional teams supporting IT projects was foreign. The program funding that was allocated to the digital transformation was distributed to the functions and my team was mostly disbanded. What remained was a small team of project managers tasked with leading continuous improvement efforts. The top-down ability to drive change disappeared and we had to innovate and influence others to accomplish our work. It’s been nearly 3 years and I can say that change is still possible, but it looks different.

If you find yourself in a similar job scenario where you need to improve the business without much direction, or you are in middle management and seek to make things better, these tips can help.

Ask Questions to Find Problems

Chances are that there is no shortage of issues within a business. If you don’t have a specific problem in mind, then seek to find one though interviews with your teams or your co-workers. Ask about what keeps them up at night, or what do they find the most frustrating. You may need to dig deep using a 5-why approach. In this approach, you ask why several times until you get to the root of an issue that can be solved. When you get to a solvable problem, ask what they have done to fix the problem previously. This will give you a sense that the problem is worth solving, and what has been tried in the past.

Break Projects into Pieces

In project management, the work is broken down into work breakdown structures or WBS. The WBS defines the overall scope of the project and breaks down the work to plan the schedule, resources, and budget. In a scenario where the project is not tops-down, or the project sponsor is not defined, you can think about splitting the project into minimal viable projects. For example, if there is a project to improve the ergonomics in the office, rather than focus on the entire setup, select one element to focus on. Finding funding to provide ergonomically friendly keyboards is easier because of the lower cost and effort. Once the keyboard project is finished, propose adjustable chairs, or monitor stands. Little by little, the incremental efforts add up until eventually enough has been funded that the standing desks are more agreeable.

Look for Low Cost, Low Code IT Solutions

Recently, I met another business transformation / continuous improvement leader from a similar sized company. He was in the same scenario with little direction and low budget. By working with the organization to find problems to solve, he leveraged the Microsoft Power Apps suite to create apps himself to solve the problems. There are several options for low code/no code software development. IT experience is not required and there are plenty of training videos on YouTube.

Be Patient

Chances are that if you have the ambition to drive change from the middle, you are results oriented. I personally struggle with patience and constantly seek instant gratification. It’s important to level-set your expectations from the beginning that things take longer when driven from the middle. If work is out of your control, move onto something else while you wait. For example, I used a change request process to implement some changes in IT. The project was put into the queue and wasn’t executed for 7 months. My team moved onto other projects while we waited. Eventually, the IT team caught up and we had solved 2 different problems in the meantime. Be patient and keep going.

Think Like a Marketer

I didn’t understand the power of connecting with my audience, aka my leaders until it was too late. My passion is infectious, and I mistook energy for buy-in. When I presented machine learning results and interactive diagnostic tools, my leaders appreciated the passion, but didn’t understand what I was saying. They didn’t know what to do about it either and couldn’t help me clear roadblocks. It is extremely important to spend time understanding your stakeholders and tailoring your message according to their style. The manager who didn’t care for my data analytic detail, was more interested in who I was working with and what were the results. I could have saved us both time by cutting to the chase and letting him know what he wanted to hear, or what he needed to hear to willingly help.

Over the years, I’ve seen many people fit the grumpy co-worker mold. Always mumbling under their breath or complaining about things continuing to be a pain. Things don’t need to stay the status quo. I have had several surprising successes on projects this year, including $2.5M in funding, because of the tips described above. Make incremental, intentional, small changes and eventually you won’t believe how far things have come.

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Creating Solutions to Reduce Waste

Guest writer Sara Hanks takes readers through the process of finding solutions that work for a team in “Creating Solutions to Reduce Waste.”

Although it has been 15 years, I remember the day clearly. It was my first opportunity to participate in a manufacturing Kaizen event, facilitated by a Japanese Sensei consultant. 20+ participants were divided into smaller teams of 4-5 people, with each team focusing on an area of the shop. I was selected as the team captain, as I was the most vocal person. After a couple days of analyzing the waste associated with the current state, we were instructed to identify solutions. I shared my perfect idea for a solution and the team agreed with the recommendation. My competitive side wanted to be the first team to accomplish the task, so I was relieved that the team was onboard. 

The Sensei, along with the leaders, would spend time visiting each team. When they stopped to check in with our team, I proudly shared our perfect solution. The Sensei was not happy, and I was mortified to be corrected in front of my leaders. He explained the 7 Ways Idea Generation methodology and requested that we return to brainstorming. My team generated 6 more ideas and used criteria such as impact and effort to down select to a single idea. It turned out that my perfect idea was not the final decision of the team.  

Hey, failure is one of the best instructors! While I learned a few things that day, the most important lesson was the power of divergent thinking. Specifically, divergent thinking from a diverse group of individuals will create the best solutions. In my process mapping and continuous improvement action workouts, I use creative thinking exercises, silent brainstorming, and an evaluation process to select the best solutions. 

Leveraging Creative Thinking for Developing Solutions 

“It turns out that creativity isn’t some rare gift to be enjoyed by the lucky few—it’s a natural part of human thinking and behavior. In too many of us it gets blocked. But it can be unblocked. And unblocking that creative spark can have far-reaching implications for yourself, your organization, and your community.”

― Tom Kelley, Creative Confidence: Unleashing the Creative Potential Within Us All 

When it comes to solutions, we tend to default to the ideas that have already existed. It’s hard to think outside of the box and be innovative because people tend to stop at the obvious solution. Introducing unrelated, creative exercises into an action workout can unlock creative thinking and help create new ideas. One of my favorite ways to spark creative thinking is to solution the worst possible idea first. Creating the worst idea does two things: 1) removes barriers by allowing the craziest of ideas to exist and 2) loosen up the team and help them feel more comfortable brainstorming ideas. 

There are several exercises available on the internet, so I recommend selecting 1-2 that fit within the context of the solution building. A coloring activity may not work for a meeting that is conducted virtually, for example. Once you’ve warmed up the group using one of these exercises, brainstorm solutions. 

Silent Brainstorming for Idea Generation Equality 

Silent brainstorming is used to generate ideas individually, while everyone is quiet. Participants can think without distractions or influence from other people. Groupthink is avoided and everyone has an equal opportunity to contribute to the solution. If the group is in a conference room or other common area, sticky notes are a good place to record ideas. Limit one idea per sticky note. If the group is located remotely, then ideas can be written down digitally. Remember the intent is to brainstorm without sharing, so make sure the ideas are captured locally vs. a shared platform. I recommend at least 30 minutes of brainstorming to ensure people can think their ideas through. After the silent brainstorming is completed, everyone can share their ideas with the larger group. As the team shares ideas, similar solutions emerge, which can be combined into single solutions. Once the solutions are identified, it is time to down select the idea. 

Selecting the Best Solution 

Selecting the best solution can be done a few different ways. Here are three examples:

1. Impact – Effort matrix: the ideas are plotted on a grid. The ideas in quadrant 1 are no-brainers and the ideas in quadrant 3 can be discarded. The others are open to discussion.
2. Voting: with voting, each person receives 7-10 votes. A person can use all their votes on a single idea or spread them across multiple solution ideas. Voting should be silent to prevent groupthink, as with silent brainstorming. The ideas with the most votes are selected for implementation. If the cost to implement the solutions vary, I recommend taking the top ideas and assessing them in an impact – effort matrix. 
3. Assessing each solution against a set of predefined criteria. The criteria can include impact and effort but are expanded to assess other requirements. Safety, compliance, security, and quality may be included. Typically, the criteria are defined up front in the project charter as critical to quality items, benefits, or both. For each idea, score the idea against the criteria – I prefer a 1, 3 9 scale to differentiate the most applicable items. The total score for each idea is calculated – the highest scored ideas should be implemented.

After the solution(s) are selected for implementation, create a set of action items, owners, and dates for the critical next steps. Schedule follow-up meetings to ensure the actions are closed and identify any unforeseen roadblocks. Most importantly, don’t forget to enjoy implementing the innovative solutions that you and the team created!

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