Continued from page 1
While writing All You Gotta Do Is Ask, I would share thoughts and ideas with Allen. Following is one of
implemented ideas that Allan recently shared with me:
BEFORE IMPROVEMENT Cotton rags are used to clean lubricant off machines, parts and operators hands. Employees collect rags in a fireproof can and periodically during
week, will come to a central location in
plant to count out their rags, one by one. One operator submitted and had approved an IDEA to put a small counter on his fireproof can. As he was putting rags into
can, he simply toggled off how many rags went into
can. When he went to drop off
rags at
central location, all he had to do was dump
rags.
Allan was reading
Quick & Easy Kaizen board, where IDEAS are posted for sharing, and read about
counter idea. He then encouraged an employee to speak to
person in charge of
recycling program for
rags and investigate why there was a need to count
rags at all. It turns out that approximately 15 years prior,
supplier of
rags was
only one keeping track of
rag counts and there were discrepancies. Part of
solution was to have both parties count
rags for a short period of time to determine what was happening. However,
counting continued from then on.
AFTER IMPROVEMENT All operators in
plant have been asked to discontinue counting rags.
EFFECT Operator’s jobs are easier and from one IDEA to make an operator’s job easier by adding a counter to his can,
company has uncovered over 150 hours per year to be more productive. Some people may be embarrassed that such a miscommunication would happen and feel uncomfortable sharing it. However, Allan says, "lets expose
waste without pointing fingers, reap
reward and learn from our mistakes as
only true mistakes are those which we don't learn from".
Allen continues to lead his people to find small improvements to make their job better, large improvements will also be uncovered. He was recently promoted to Assistant Production Supervisor.

Chuck Yorke is an organizational development and performance improvement specialist, trainer, consultant and speaker. He is co-author of “All You Gotta Do Is Ask,” a book which explains how to promote large numbers of ideas from employees. Chuck may be reached at ChuckYorke@yahoo.com