Friday, March 31, 2006

BofA efficiency leader makes executive suite shift

Milton Jones, bank's pioneer in Six Sigma, now reporting to CFO

Charlotte Business Journal - March 24, 2006by David MildenbergStaff writer

Milton Jones, who has led Bank of America Corp.'s vaunted productivity push for three years, is moving to a new job reporting to the company's chief financial officer.

Jones is now chief operating officer for the bank's chief financial officer, Al de Molina. His tasks include overseeing the company's financial systems and processes, supply-chain management, MBNA financial systems transition and finance support for China Construction Bank.

BofA acquired MBNA for $35 billion earlier this year, while it paid $3 billion last year for a minority interest in the Chinese bank.

Jones' replacement as global quality and productivity executive will be named shortly. That individual will report to Barbara Desoer, who heads BofA's Global Technology, Services & Fulfillment unit.

The change suggests a lower profile for BofA's productivity efforts, given that Jones and his predecessor, Chuck Goslee, reported to Chief Executive Ken Lewis.

But spokesman Terry Francisco says productivity improvements remain central at BofA.

"We've made the cultural change to adopt Six Sigma," he says, referring to the productivity program BofA has employed since 2001. "The high visibility of that position did a great job informing people of the importance of the effort. This is a logical next step."

BofA has been the most vocal Six Sigma proponent among major U.S. companies in recent years, with Jones leading the charge, says Michael Marx, research director of isixsigma.com, an online trade publication.

"He's been the face of Six Sigma," Marx says.

Jones' experience "forms the perfect combination of skills and expertise to help us accelerate the work we're doing to build our financial systems and processes for the future," Lewis said in a prepared statement to employees.

Jones is one of eight senior managers listed on BofA's Web site. The other seven report to Lewis.

Jones is the highest-ranking African-American executive at BofA and heads its diversity advisory council. He joined the company in 1977 and was president of its Georgia bank before taking the productivity post in April 2003.

Desoer oversees BofA's systems and back-office operations, making productivity a natural addition, Francisco says.

Since 2001, BofA has promoted its Six Sigma program, a quality-improvement plan developed at Motorola Corp. in the 1980s and later popularized by General Electric Co.

At a Six Sigma conference earlier this year, Jones said the productivity efforts at BofA have resulted in savings topping $1 billion annually.

He added that Six Sigma is a key part of BofA's goal to become the nation's most admired company.

With Jones' shift, three fewer executives report directly to Lewis than a year ago. Former top marketing executive Cathy Bessant now reports to Gene Taylor, BofA's top commercial banking executive. Ex-CFO Marc Oken retired last year, with former investment bank chief Molina taking over his post.

BofA's efficiency ratio -- the percentage of its noninterest expense divided by net income -- dipped to a record-low 49% last year. Lewis credits the Six Sigma program for much of that success.

Have you adopted Six Sigma yet?

AVISHEK TOPNO

INDIATIMES NEWS NETWORK[ FRIDAY, MARCH 31, 2006 12:00:28 AM]

To understand what is Six Sigma, first let us be clear about what it is not. It is neither a secret organisation nor a form of marshal art.

For many companies, Six Sigma is a measure of quality with a continuous improvement programme aspiring for perfection.

Six Sigma is a disciplined, data-driven approach and a methodology for identifying and eliminating defects (driving towards six standard deviations between the mean and the nearest specification limit) in any process -- from manufacturing to transactional and from product to service.

Commonly defined as 3.4 defects per million opportunities, Six Sigma can be defined and understood at three distinct levels: metric, methodology and philosophy.

What is the history of Six Sigma?

In the early and mid-1980s with Chairman Bob Galvin at the helm, Motorola engineers decided that the traditional quality levels -- measuring defects in thousands of opportunities -- didn't provide enough granularity.

Instead, they wanted to measure the defects per million opportunities. Motorola developed this new standard and created the methodology and needed cultural change associated with it.

Six Sigma helped Motorola realise powerful bottom-lines - in fact, they documented more than $16 billion in savings as a result of Six Sigma.

Since then, hundreds of companies around the world have adopted Six Sigma as a way of doing business. This is a direct result of many of America's leaders openly praising the benefits of Six Sigma.

Leaders such as Larry Bossidy of Allied Signal (now Honeywell), and Jack Welch of General Electric Company. Rumor has it that Larry and Jack were playing golf one day and Jack bet Larry that he could implement Six Sigma faster and with greater results at GE than Larry did at Allied Signal. The results speak for themselves.

Why do we need Six Sigma?

Increasing global travel and access to more information about what is happening in the world contributes significantly towards raising customer awareness.

As soon as customers have a good experience with a business, their expectations are raised and they begin to demand similar good experiences with other businesses.

Thus the customer expectations keep rising. Time to market has become critical. Product development cycles are getting shorter and shorter.

Order placement to merchandise delivery time is getting shorter. Customers are demanding cost reduction. With a vibrant economy, it is a real challenge to retain good employees.

Finally, managing continuous change is a significant challenge. Therefore, management is always looking for ways and means to address all these challenges.

That is where Six Sigma comes into the picture. Successful implementation of Six Sigma can meet these challenges and create benefits on all levels, for all players.

How does Six Sigma work?

There are five steps to Six Sigma:

Define: A Six Sigma project team¡ªled by a black belt¡ªidentifies a project based on business objectives as well as customer needs and feedback.

The team identifies CTQs (critical to quality characteristics) that the customer considers to have the most impact on quality. It also separates the "vital few" from the "trivial many" (the projects that will have the most impact versus those that could stand improvement but are not critical).

Measure: The team identifies the key internal processes that influence CTQs and measures the defects currently generated relative to those processes.

Analyze: The team discovers why defects are generated by identifying the key variables that are most likely to create process variation.

Improve: The team identifies the maximum acceptable ranges of the key variables and validates a system for measuring deviations of the variables. The team modifies the process to stay within the acceptable range.

Control: Tools are put in place to ensure that the key variables remain within the maximum acceptable ranges over time.

What are the costs and benefits of Six Sigma?

In the world of Six Sigma quality, it takes money to save money using the Six Sigma quality methodology. You can't expect to significantly reduce costs and increase sales using Six Sigma without investing in training, organizational infrastructure and culture evolution.

Sure you can reduce costs and increase sales in a localised area of a business using the Six Sigma quality methodology -- and you can probably do it inexpensively by hiring an ex-Motorola or GE Black Belt.

You can think of that scenario as a "get rich quick" application of Six Sigma. But is it going to last when a manager is promoted to a different area or leaves the company? Probably not.

If you want to produce a culture shift within your organization, a shift that causes every employee to think about how their actions impact the customer and to communicate within the business using a consistent language, it's going to require a resource commitment.

It takes money to save money.

How to implement the Six Sigma training and for whom?

Implementing Six Sigma within an organisation is similar to implementing any other company-wide initiative. Determining the content and framework, developing the materials, and rolling it out to the company is only half of the necessary work.

The other half is changing the culture.

Six Sigma Training is one of the most important factors that contributes to and helps modify and shape an organization's culture.

This article will help identify who in your organization is required to be Six Sigma trained and what type of Six Sigma training they should receive.


Senior Management

Senior Management, also known as 'C-Level Management' (CEO, CIO, CFO and peers), are the individuals that set, communicate and drive the overall business objectives.

They are also the individuals that are required to incorporate Six Sigma objectives into their operational plans. Examples of objectives might include:

X% of employees through Six Sigma training by a certain date

Y% reduction in defects for all customer visible processes by quarter end

Z% in back-office projects savings by year end

Six Sigma training for Senior Management should include a program overview, business and financial benefits of implementation, real-world examples of successful deployments, specific application to business/industry, and the required Six Sigma training and tools to ensure successful implementation.

Depending on Senior Management's time availability and their desire to learn the details, Black Belt training is also recommended.

Functional / Process Managers

Functional and Process Managers are the level of management directly reporting to the Senior Management.

Depending on the size of the organisation, they might include functional managers from areas such as human resources, finance and training, and process managers from areas such as assembly, production and call center.

These managers are sometimes referred to as 'sponsors' and 'champions' because they are known to champion the cause within their business organization.

These champions translate Senior Management's strategic directions into tactical objectives and actions with the help of their Quality Leader and Project Leaders. Six Sigma training for Functional and Process Managers is more detailed than that for Senior Management.

Topics include the Six Sigma concept, methodology, tools and requirements to ensure successful implementation within their organization.

Quality Leaders

Quality Leaders, also known as Quality Managers and Master Black Belts, help Functional and Process Managers set and lead the Six Sigma vision within their specific areas.

They maintain rolled up budgets, track business cost savings, ensure training goals are met, coach Functional and Process Managers, Project Leaders and Employees, review projects at milestones, share best practices, and ensure appropriate use of tools and methodologies.

Six Sigma training for Quality Leaders includes detailed information about the concept, methodology and tools, as well as detailed statistics training and computer analysis tool use. Depending on the instructor, the duration is usually between three and four weeks.

Project Leaders

Project Leaders, also known as Black Belts, implement the Six Sigma methodology and tools within the business.

They lead the intra- and inter-function projects, maintain time lines and budget, determine appropriate tool use, perform analyses, and act as the central point of contact for specific process improvement projects.

Six Sigma training for Project Leaders includes detailed information about the concept, methodology and tools.

Depending on the instructor, the duration is usually between two and four weeks, and may include one of more weeks in between sections. Statistics is included in the agenda, but typically does not include as much detail as that provided to Quality Leaders.


Employees

Employees, also known as Green Belts, may also take Six Sigma training courses developed specifically for part time Project Leaders.

Six Sigma training for Green Belts is similar to Black Belt training, but shorter in duration because less detail on complex tools and statistics is provided. Employees are instead told to ask their Black Belt for help in specific areas.


How does the Six Sigma organisational structure work?

Roles and responsibilities

Quality Leader/Manager (QL/QM) - The quality leader's responsibility is to represent the needs of the customer and to improve the operational effectiveness of the organization.

The Quality function is typically separated from the manufacturing or transactional processing functions in order to maintain impartiality. The quality manager sits on the CEO/President's staff, and has equal authority to all other direct reports.

Master Black Belt (MBB) - Master Black Belts are typically assigned to a specific area or function of a business or organization. It may be a functional area such as human resources or legal, or process specific area such as billing or tube rolling.

MBBs work with the owners of the process to ensure that quality objectives and targets are set, plans are determined, progress is tracked, and education is provided. In the best Six Sigma organizations, process owners and MBBs work very closely and share information daily.

Process Owner (PO) - Process owners are exactly as the name sounds ¨C they are the responsible individuals for a specific process.

For instance, in the legal department there is usually one person in charge -- maybe the VP of Legal -- that's the process owner. There may be a chief marketing officer for your business -- that's the process owner for marketing.

Depending on the size of your business and core activities, you may have process owners at lower levels of your organizational structure.

If you are a credit card company with processes around billing, accounts receivable, audit, billing fraud, etc., you wouldn't just have the process owner be the chief financial officer, you would want to go much deeper into the organization where the work is being accomplished and you can make a big difference.

Black Belt (BB) - Black Belts are the heart and soul of the Six Sigma quality initiative. Their main purpose is to lead quality projects and work full time until they are complete.

Black Belts can typically complete four to six projects per year with savings of approximately $230,000 per project (see earlier reference). Black Belts also coach Green Belts on their projects, and while coaching may seem innocuous, it can require a significant amount of time and energy.

Green Belt (GB) - Green Belts are employees trained in Six Sigma who spend a portion of their time completing projects, but maintain their regular work role and responsibilities.

Depending on their workload, they can spend anywhere from 10% to 50% of their time on their project(s). As your Six Sigma quality program evolves, employees will begin to include the Six Sigma methodology in their daily activities and it will no longer become a percentage of their time -- it will be the way their work is accomplished 100% of the time.


Is Six Sigma the answer to all your dreams?

If you are already operationally excellent and want to squeeze out defects and increase efficiency, Six Sigma is for you.

If your business is built on intangibles, stuff that's awfully hard to subject to statistical analysis, then Six Sigma is not for you. If you want to be a product leader competing primarily on quality, but not first-to-market, then get out your wallet.

Beware, though: Data collection is the Achilles' heel of many a Six Sigma effort. This sort of woe, often caused by an amalgamation of disparate computer platforms thrown together in a merger or acquisition, is common at the large companies that have been early adopters of Six Sigma.

Making matters worse, there is currently no software program that goes across a variety of computing platforms to collect data for Six Sigma analysis.

©Bennett, Coleman and Co., Ltd. All rights reserved.

Thursday, March 30, 2006

OSHA Alliance with Dow Leads to Case Studies on Motor Vehicle Safety

3/30/2006 11:19:00 AM

To: National Desk

Contact: Frank Meilinger of the Occupational Safety and Health Administration, 202-693-1999

WASHINGTON, March 30 /U.S. Newswire/ -- Reducing motor vehicle accidents (MVA) is the focus of a new pair of case studies that are the product of the Occupational Safety and Health Administration's (OSHA) Alliance with The Dow Chemical Company (Dow). Through the Alliance, originally signed in 2003, Dow worked to identify the root causes of MVAs and implement effective motor carrier and vehicle safety programs.

"These case studies offer useful information and demonstrate the correlation between safety and health excellence and business excellence," said Jonathan L. Snare, Acting Assistant Secretary of Labor for OSHA. "They provide practical examples of how this correlation can enhance worker safety and health, improve employee morale, and increase quality, efficiency and profitability."

-- Motor Carrier Safety Case Study: A Collaborative Approach to Reducing Motor Carrier Incidents describes how Dow worked with one of its motor carriers to implement a new behavior-based safety program to reduce rear-end collisions. Drivers served as observers of critical causes and submitted their data anonymously. The data were collected, posted, and discussed by the drivers during safety meetings. A group of drivers met to identify the causes of certain types of accidents, evaluate them and establish preventative measures. The goal for the project was an annual 60-percent reduction in rear-end collisions, but in the first year, the reduction was 82 percent.

-- Motor Vehicle Accident Case Study: The Dow Chemical Company's Use of "Six Sigma" Methodology traces how a Dow business unit used a problem-solving methodology called "Six Sigma" to find the root causes of MVAs and offer innovative ways to reduce them. At Dow, MVAs were the largest single cause of occupational fatalities for the period 1992 through 2002. Dow implemented its program in 2002 and by 2004 the company reduced its MVAs by 30 percent.

The case studies are available on OSHA's Alliance Program Website and can be used in business and other training curricula that address management skills and occupational safety and health issues.

Employers are responsible for providing a safe and healthful workplace for their employees. OSHA's role is to assure the safety and health of America's workers by setting and enforcing standards; providing training, outreach, and education; establishing partnerships; and encouraging continual process improvement in workplace safety and health. For more information, visit http://www.osha.gov.

This news release text is on the Internet at http://www.osha.gov. Information on this release will be made available to sensory impaired individuals upon request. Voice phone: 202-693-1999.

Tuesday, March 28, 2006

Virulent new culture needed to cure what is ailing Merck

The CEO's diagnosis may be the heart-starter the drug maker needs, writes Christopher Bowe

March 28, 2006


DICK Clark is on the A-list. The chief executive of Merck is receiving invitations from the US President, the UN Secretary-General, congressmen, senators, boards and councils. People now recognise him in public.

He suspected life would change after he became head of the US drug maker last May, but he never knew by how much.

Sitting in the modest chief executive's conference room in Merck's Frank Lloyd Wright-style headquarters in central New Jersey, Clark is a reluctant celebrity. He speaks quietly, and lowers his voice as the conversation touches on critical topics. He may have served as a lieutenant in the US Army in the early 1970s, but he appears uncomfortable under questioning.

"Whether they are different associations and boards or government officials, I underestimated tenfold the external demand that is placed on a CEO," he says.

The remark says much about the man charged with reviving a company that has fallen from grace following a series of missed targets, litigation over its withdrawn painkiller Vioxx and expiring patents on some of its high-earning drugs.

Throughout his career, Clark has been far from the limelight, working for 30 years in the mundane area of drug manufacturing and in Merck's low-margin former Medco unit, a manager of prescription drug benefits.

Now the corporate insider must put himself at centre stage if he is to overhaul Merck's culture and convince its 65,000 employees that change is essential.

"What we're trying to do is regain our leadership position in the pharmaceutical industry," says the 60-year-old Clark, who has spent most of his career at Merck.

"And the fact is culture eats strategy for lunch ... You can have a good strategy in place, but if you don't have the culture and the enabling systems that allow you to successfully implement that strategy ... the culture of the organisation will defeat the strategy."

In the early 1990s, Merck was the world's No1 drug maker and the envy of its rivals. But now it ranks a lowly eighth, far below companies it considered an afterthought a decade ago.

Merck admits it suffered from a culture of arrogance, particularly in its research arm and, with few blockbuster drugs in the pipeline, its business prospects have been dimming over the past five years. Earnings have either fallen or remained flat over that time, often disappointing Wall Street.

Meanwhile, it has scrambled to find new products to make up for the patent expiry in June of its biggest drug, Zocor, for cholesterol. In 2008 the patent expires on another big earner, the osteoporosis drug Fosamax.

Vioxx, too, has been a huge setback. Merck has been besieged by almost 10,000 lawsuits, potentially representing billions of dollars in liability, over the blockbuster drug that it withdrew in 2004 - after finding it increased the risk of heart problems.

These troubles hastened the retirement of Raymond Gilmartin, former chairman and chief executive, last May. But Clark's selection was not welcomed with applause on Wall Street. The appointment of the life-long company man was seen as proof that Merck's insular culture would not change, even in desperate times.

Clark counters that his experience has been vastly underestimated. His time in manufacturing, he says, gives him the skill of wringing efficiencies out of the business.

Further, his spell at Medco, which worked closely with other drug makers and therefore operated with a firewall between it and Merck, allowed him to see the parent company from the outside.

"If I didn't go through those combinations, if I didn't actually step outside of Merck and look back in, I don't think anybody in this company would've had the same intensity for change," Clark says.

So how does he plan to turn Merck around? The first step is a radical shift in culture, he says, from a change in the way employees work together to instilling greater accountability in every corner of the group.

Clark wants to create an aggressive, disciplined and efficient environment in a company regarded in industry circles as passive, prim and academic. Without such a shift, he believes, Merck will not change fast enough to deal with its own problems, never mind the growing pricing, governmental and regulatory challenges facing the sector.

"There's a little bit in the culture of 'this too shall pass'. And it's not passing, it still exists, and the environment is going to get much more intense," he says. "Our theme with our new strategic plan is a plan to win. We felt like we were trying not to lose, instead of trying to win."

Clark says that there have long been "enough signals" that Merck needed changing, including rumblings from Wall Street, pricing pressures and a slow reaction to intensifying government scrutiny. He believes "metrics" should have been in place at least five years ago to watch for "early warning signals" in the business.

He says Merck should have aggressively cut costs, particularly in its marketing arm, in the last five years. But the industry, not only Merck, came late to such cost consciousness, he adds.

Research could have been helped too, he says, as the increased requirement for productivity in research raised questions "whether we needed to bring in another wave of scientists and clinicians to help us".

The sales and marketing arm also lacked accountability for its actions. "You know we disappointed 'The Street' several times with our numbers and nothing happened to the commercial model. We didn't change how we were organised, or change leadership, or issues like that," he says.

Clark's mission began in September. Teams of employees were asked to present business cases to senior managers to test possible directions for the company, such as whether to build a generic drug business. The review concluded that Merck should remain a pure-play drug company. But Clark says the process was vital, as it showed the 200 senior executives that Merck would now operate in an atmosphere where assumptions could be openly questioned by anyone.

"The way we would potentially do it in the past was: 'Why aren't we in the generics business?' And the answer you'd get is: 'Well that's not the business we're in.' And people would give you a little laugh and a smirk," he says. "That's not a satisfying answer."

He has launched several initiatives to boost communication: he will brief employees around the world through webcasts; company strategy will be set out on a single sheet of paper; and a scorecard will be developed showing everything Merck needs to accomplish in 2006, with quarterly updates on both financial and strategic objectives.

He also plans to share this scorecard with investors in the hope of erasing what he calls Merck's "credibility gap" with Wall Street.

In drug research he will focus Merck on just nine disease areas instead of 32. Manufacturing operations will be restructured and Merck will rely more on technology instead of sales representation to market drugs. Six Sigma, a quality-control system, will be applied in research to speed drug development, and elsewhere in the company.

Clark has also changed the way the company sets its earnings projections. Formerly set by top managers, projections are now suggested by lower-level teams.

"It wasn't like Dick Clark said: 'We're going to have double-digit growth, go out and find it!' We tested it and tweaked it ... but it was legitimate and we believe in it, so let's go public with it. And that's the first time we'd done that as a company, ever," he says.

He has pledged at least 10 per cent compound annual earnings growth by 2010, helped by cost cuts and two crucial forthcoming products: Gardasil, a vaccine for cervical cancer, and Januvia, a diabetes drug.

Clark says the long-range target is "important to put a stake in the ground", believing the company needs to prove it could be held accountable by investors and employees.

Clark's strategy will determine his legacy. He turns 65, the company's retirement age, in March 2011. His last six years of service will make him either the hero of Merck or another scapegoat for its decline.

Outside the office, Clark's reading preferences include works on the American Civil War and Abraham Lincoln, whom he admires for his ability to succeed despite naysayers, rivals and unsupportive members of his own government.

His predicament differs, he says, since the company is rallying behind him. But outside, detractors remain.

If he succeeds, he will have the satisfaction of knowing he set Merck on a path to growth -- and making a cultural change that he hopes will be talked about 100 years hence.

"I hope they'll say: 'Remember back last century when Clark did that.' ... And if we do that, I think by 2010 you'll see an article, maybe in the FT, that says 'Merck is back'."

Sunday, March 26, 2006

Preparing the organisation for change

To quote an anonymous author, "Change is inevitable except from a vending machine". Most individuals and organisations do not readily embrace change. Often, they take steps to avoid it. In many cases, individuals expend more energy resisting change, without realising that it would take lesser energy to just change. It is human nature to accept status quo and feel uncomfortable about the unknown state brought on by change. A plethora of research exists on the topic of change and change management. Thousands of consultants are employed because of the inevitable and constant need for effective change management in organisations. And within organisations, effective change agents are desired commodities.

Leadership Commitment for Change

As cited in the previous chapters, leadership commitment for an organisational activity, including change, is a key ingredient to effectively managing an organisation. Leaders must be actively engaged and "walk the talk". Leaders should create or foster a culture, where change, spurned by continuous improvement, is expected, and desired behaviours are rewarded. Leaders also need to assign and support effective change agents within an organisation, and hold key members within the organisation, responsible and accountable for achievement of results and continuous improvement. Status quo should not be tolerated.

The old adage "manage change or change management" cannot be more true. Unfortunately, most organisations and people, don't deal with change particularly well. In addition to leading by example and supporting change within an organisation, leaders need to help create an environment where the need for change is understood by everybody. Sometimes, this is communicated in a crisis mode, such as by an organisation in dire financial straits and about to go out of business. By this time, it is probably too late to change. And the key stakeholders - employees, shareholders, communities, and so forth - will hold the leaders accountable for not having made the necessary changes to keep the organisation viable and successful.

As will be discussed later in this chapter, leaders need to create or reinforce a culture that promotes change. Employees will constantly invoke the "WIIFM" adage —"What's In It For Me?" Leaders, working with their change agents, need to help the entire organisation understand the need for change and the impact it will have on all individuals and parts of the organisation. One way of doing this is by estimating the magnitude for change.

Change agents within an organisation are rare, yet, desired entities. They must effectively implement changes throughout the organisation, knowing that they will face resistance from every quarter. Change agents must serve as extensions of the senior management. The typical attributes, change agents must posses include an ability to get things done by others, respect for and by the organisation, and demonstrated history of achieving results and meeting commitments. Six Sigma Black Belts are taught change management as part of their overall training and make acceptable change agents in most cases. They identify new ways of performing old operations and implement these changes in various parts of an organisation.

Estimating the magnitude for Change

In most organisations, change occurs on a regular basis. However, its magnitude varies, and in many cases, organisations do not notice the changes that have taken place. Most large organisations manage change through period reorganisations or restructuring. Organisations may restructure themselves every 12, 18, 24, or 36 months. Once they change, the new structure and behaviours settle for a period of time while everyone gets accustomed to the new structure. This stepwise approach to change is depicted by the stepping stone line Gradually, the changes become more and more frequent, larger and more radical, or the organisation will become less suited for the business environment. However, since the environment is acknowledged to be changing exponentially, such an approach means the organisation will always lag behind the ideal situation. The employees are sure to be frustrated by the tumultuous, periodic changes.

Perhaps an organisation views the useful life of its technological base as 10 or 15 years, and depreciates and replenishes the technological base accordingly. Perhaps an organisation invests in a week or two of training each year, and relies on it to keep employees "up to speed". Perhaps an organisation relies on the marketing strategy of "milking" mature products rather than rapid product innovation. All of these viws will lead to a constant rate of change of 10 to 15 percent every year. This rate of change is guaranteed to eventually lead to mediocre organisational performance that ensures that the organisation significantly lags behind the business environment.

If the environment is changing exponentially and organisations are changing slowly, in a stepwise or gradual fashion, facing future shock is inevitable. Often, the reality check takes the form of a merger or acquisition. Sometimes, the future shock takes the form of corporate bankruptcy. In some cases, the future shock takes the form of radical downsizing to hang on to one or two "core competencies". And, often, the future shock is marked by a significant decline in stock price with investors losing confidence in an organisation. But if an organisation pursues an appropriate strategy, the future shock may never happen. Change, or expectations for change, can come to an organisation through many different means. Some examples include:

Customer Expectations

Customers are dynamic and always changing. As individuals, we expect new products and services to be better and faster than the previous models or versions. We expect better service and technical support. Our expectations are continually increasing, as new levels of performance become the norm. Consumers do not expect product capability and service to decline. To meet these rising expectations, businesses must continually improve and innovate at a rate, at least, equal to the increase in customer expectations.

Technological Change

The rate of change in technology continues to accelerate. No longer are there "high technology" businesses; all businesses are directly affected by rapid technological change. Customers expect a new personal computer to have a faster processing speed, more memory, higher resolution, and better software. These expectations are uniform across almost all product and service industries. The Internet, has changed the way business and support services are conducted. And there are certain to be big changes in the consumer use of the Internet when web TV becomes more widespread. The only thing certain is that there will be new and currently unavailable technological advances, that will be in widespread use in five years.

According to the survey of CEOs, conducted by the US Department of Commerce, the second most critical issue in North America and Europe was dealing with rapid technological change. This was the most frequently identified issue in Asia. The issue of technological change included both rapid change in products as well as underlying systems. The implication is that functional life cycles have become shorter and shorter. For example, an old 486 computer with a Windows 3.1 operating system may still perform as well as it did in 1995, but it surely has been functionally obsolete for years.

Global Competition

The rate of growth of international trade among industrialised economies has been twice the rate of domestic economic growth for years. The issues that concerns CEOs today are related to globalisation and global competition. According to the survey conducted on behalf of the US Department of Commerce, many CEOs felt that within the next decade, foreign competition would pose a serious threat to their companies. The reason is that customers have a wide array of product and services to choose from. Country of origin of a product is less and less of a concern to customers and is often unknown. In fact, many "foreign" products have a higher domestic value added content than traditional "domestic" products. Customers select from the products of the very best global suppliers, guaranteeing tough, global competition in all major economies.

Never before has it been easier to do business on an international basis. Companies specialised in dealing with customers, tariff, and shipping issue make the process of delivering goods and services to another country possible for organisations of any size. Many marketing plans being put in place today are global in nature. The ease of doing business internationally has spurned global competition in virtually every market segment.

Customisation and Niche Players

Customers are demanding more and more customised products and services, forcing suppliers to produce more customised products that fit a customer's specific needs. This change in customer requirement is forcing organisations to change their productive processes to become more flexible and adaptable. There are many more "niche" markets (and market players) that larger organisations have trouble adapting to. Economic order quantities are not driven by a formula in an economics book; production levels are driven by customer demand that can change quickly.

Implementing Strategic Change. Tools for Transforming an Organization. Steven H Hoisington and SA Vaneswaran. Tata McGraw-Hill Publishing Company limited, New Delhi

Sustaining Six Sigma and Spreading The Success

Let's imagine that your initial Six Sigma projects have achieved their goals. Now what? Six Sigma is dedicated at making permanent changes to re-align your process through the implementation of metrics. It enables you to know what you can expect from your people and processes. By maintaining and controlling that performance, you keep the value and purpose of your Six Sigma efforts in the forefront of all your activities, both today and into the future. Six Sigma helps you identify what you don't know, indicates what you should know, and helps you reduce defects that cost time, money, opportunities, and customers. Will you achieve a six-sigma level of quality, only 3.4 million defects per million opportunities—99.9997 percent perfect? That's really not the question. The question is “How much are process variations and defects costing you?” If you don't have that knowledge, you don't have the power to reduce or eliminate those problems and achieve significant savings. This chapter is about how to follow-up on your first Six Sigma successes, how to build upon those results, how to keep the energy level high, and how to spread Six Sigma throughout the organisation and beyond.

Continue the conquests

As part of your Six Sigma commitment, you need to initiate new projects, find more dollars, raise your quality levels, and maintain the momentum of your initiative. While Six Sigma might be initiated from the top, it works because of the employees on the project teams. Thus, managers at all levels should be focused on this big question - “How can we keep employees energised on Six Sigma? “To get the best return on your investment and keep customers competitive and content, you need to move with the momentum and sustain the gain. After all, you don't make the investment in Six Sigma and take the time to train people, to select projects, and then to drill down to your costs of poor quality once. Six Sigma is ongoing; it's a constant, “living” methodology that needs to continue as long as your business does. After all, to quote Aristotle, “We are what we repeatedly do. Excellence, then, is not an act, but a habit.” Or, as an unknown philosopher has put it, “It's not a single, great, heroic deed that defines who you really are. It's the little things you do, day by day, that count.” It's helpful to break up the basic infrastructure required for successful Six Sigma into a two-year context. In the first year, you lay a foundation for success. In the second year, you follow up on your successful start and build on that foundation.

In the first year, you need to do the following:

Train the best of the best for black belt projects
Limit dropout rates to five percent or less
Develop your ongoing project list to register projected and actual saving
Set up your database to capture lessons learned
Get green belt training under way
Establish your ongoing communication plan, both externally and internally
Break even within approximately eight months after the initial training
Create compensation plans and progression plans for a full two years
Develop a common metric and reporting/ review system that evaluates and updates the status of all projects monthly.
Begin the backlog of projects and actively manage the reviews
Establish process metrics and set baseline data into strategic plans for the next year
Discover two to four master black belts upon the completion of training
In the second year, you need to do the following:

Transition all training from your outside consultant to your own resources
Have your internal master black belts train black belts
Promote training such that ten percent of the people in your organisation become green belts
Increase dollar savings by 300 percent over the first year's targets
Engage your key suppliers in the Six Sigma methodology
Build Six Sigma goals into companywide strategic plans
Hold quarterly reviews with senior management
Host certification events that reward and recognise black belt achievements
Develop compensation/ incentive plans, not just for black belts and team members, but also for upper managers, to ensure continued support
Get each black belt to work on four to six projects a year.
Promote at least some of your black belts
Create a “pull” system for the Six Sigma initiative. Publicise the benefits so widely that there's more interest in becoming black belt than space in your classes.

Determine the next year's goals in the number of black belts, green belts, master black belts, project selection, and savings projections.

As you make progress with Six Sigma, all of these elements will become routine and obvious aspects of the overall scope. However, this is where it is most important to recognise that there's no room for complacency or easing off on Six Sigma projects— sustaining their gains is critical to the continual success of your initiative. All of the items listed point in one direction: Keep it focused, keep it moving forward, and keep it in the fore-front of everything you do.

Lessons learned

It's possible to contribute to sustaining the gains obtained through Six Sigma by knowledge transfer. An organisation's prosperity depends on being able to learn at a faster rate than its competitors and to transfer and apply that learning to its operations to sustain its competitive advantage. So it's crucial to build and maintain a database of “lessons learned”. That means documenting what you have learned and achieved with projects to date and then relying on and sharing that information. Once you have fixed something, you need to be able to share what you know about it. It's important to share the lessons far and wide, not only to tout your success, but also to address similar issues elsewhere in the organisation. There's not much value in eliminating defects and keeping it to yourself— knowledge transfer needs to happen continually, both inside and outside of the project at hand.

It's important to provide coaching and training to ensure that the members of the project team transfer their knowledge to others and share information throughout the Six Sigma phases. The difficult process of managing information during Six Sigma projects can be made easier through Web-based software applications that maximise knowledge transfer and access for all members of the design project team.

Not all knowledge transfer requires technology, however, because members of Six Sigma project team come from various areas of the organisation, they can spread the word and share the knowledge more widely, taking it back home into their functions and to their co-workers. Nobody keeps success a secret. Those who have learned and applied the approach and the tools are going to be sharing them.

Communication plan

A communication plan is essential for sharing lessons and sustaining your Six Sigma success. Whether it is press releases, monthly newsletters, company intranet updates, video presentations, or quarterly company meetings, you need to get the message out regularly and conspicuously to people inside and outside the organisation.

You can report on the progress of projects, itemise actual dollar savings to date, explain Six Sigma acronyms, or focus in on the key tools. What's essential is to keep getting the word out on the benefits of Six Sigma. As you know, all levels of personnel should be familiar with the basics of your Six Sigma mission, including terminology, roles, and metrics. This is to ensure that people can “link” between the big picture and actionable items in their different areas. Again it's all about communicating, in real terms, the powerful implications of each and every project.

Keep focused on the customers

Continue to focus on the customers. Keep getting input, using means:

Customer complaints: Encourage them and review them regularly
Surveys: Target specifically the new product or service
Focus groups: Arrange sessions to discuss the new product or service
One-on-one interviews
Contextual inquiry: Test the product or service with the customers
Find better ways to get input— and ways to discover the customers' latent needs and expectations.

Six Sigma by Brue Howes. Tata McGraw-Hill

Mumbai dabbawalas take a byte

Sachin Kalbag
Saturday, March 25, 2006 01:07 IST

MUMBAI: The humble, semi-literate, yet Six Sigma certified Mumbai dabbawala got smarter. This evening, this much-talked about community will launch its website www.mydabbawala.com at a function at Vile Parle in Mumbai.

Even though the site is in its initial stages of development -- the pictures are pixellated, the design is amateurish, and it runs free on a popular web hosting site called GoDaddy.com -- the man who developed and designed the website says will soon have a section where Mumbaikars can apply for a dabba delivery service online.

“We do not want to emphasise on design,” says Manish Tripathi, a software engineer from Varanasi, who has created the site free of cost.

“The site has been built to essentially bring the regular Mumbai citizen closer to the dabbawala. By next week, you can apply online for a dabba to be delivered to your office.”

Dabbawalas have been around in the city for 115 years, but it was only after Prince Charles’ visit in 2003, and Virgin Atlantic chief Richard Branson’s visit in 2005 that the community got worldwide attention.

“The site will now take us to a different level,” feels Raghunath Medge, president of the Nutan Mumbai Tiffin Box Suppliers Association.

“We deliver nearly 1.75 lakh dabbas a day. With the site, we hope to take that number to 2 lakh.”

The association has more than 5000 dabbawalas, each earning around Rs4,000 per month. “Besides being a single point of contact with the world,” says Tripathi, “this site will help employment as it will help get more orders.”

Medge feels the site will also bust a few myths about the community. “We don’t just deliver dabbas from homes to offices and back. We have tie-ups with outlets that cater to specific communities. For instance, we deliver Rajasthani food to an immigrant from that state, or Gujarati food from a mess run by that community.”

Tripathi says there was a lot of initial reluctance to go online. It was only after his company, Bharat Petroleum, donated two personal computers on which they now learn word processing and spreadsheets to maintain databases, that they decided to become IT savvy.

“I had to force them to come and collect the PCs,” says Tripathi.

Tripathi aims to get corporate support in two ways – one, by way of donations to the dabbawalas’ cause, and the other by inviting captains of industry to write weekly columns on the website.

Medge has a bigger goal, though. “With so many restaurants running their own delivery service, competition is getting tough,” he admits. “With this site, we want to prove that we are not far behind.”

What you can do on the site
Order a dabba online (application goes live next week)
Track your order status
Learn about this history of the dabbawala community
Buy endorsed products like T-shirts, CDs, and mugs
Download wallpapers

Sunday, March 19, 2006

Improved care using a flashlight, not a hammer

By Joe Gardyasz
joegardyasz@bpcdm.com

If hospitals published a Consumer Reports-style comparison of how often they perform some simple procedures that tend to keep patients from having serious complications, the reports couldn’t be downloaded fast enough, right?

Well, there is a report out there measuring quality indicators of Iowa’s hospitals, but it has been primarily doctors, not the public, who have been sitting up and taking notice.

“What’s most interesting is that when you take these measures and release them to (the doctors), they’re freaked out,” said Dr. Tom Evans, president of the Iowa Healthcare Collaborative. “There isn’t a hospital or a physician that thinks that they’re in the lower 50th percentile. So what happens is that quality clinical measures that are released cause tremendous energy (among physicians).”

Originally formed through a partnership of the Iowa Hospital Association and the Iowa Medical Society, the Iowa Healthcare Collaborative has grabbed the attention of nearly all of the state’s hospitals and resulted in an unprecedented sharing of knowledge, even among competing organizations, Evans said. Working to implement the latest in quality improvement techniques, the group last year released its first Iowa Healthcare Report, and this year is sponsoring a number of forums to move the effort forward.

“Historically in health care, it’s been difficult to compare one health system to another, because everyone has defined quality differently,” he said.

Since 2000, however, there have been a number of successes in standardizing those measures. One of the first efforts came in 2002, when the Hospital Quality Initiative provided a set of 10 measures of clinical quality. In 2004, the National Quality Forum released 30 standardized measures of procedures proven to improve patient safety, known as the 30 Safe Practices.

“We thought (the 30 Safe Practices) was so important, we took the role of promoting it to hospitals,” Evans said. “We did a survey of all the hospitals, asking: are you aware these are out there, how important are they, and where are you with deploying these?” When 88 percent of the state’s hospitals returned the survey – an overwhelming response rate for any survey – “we knew we had some good pretty good engagement with the providers in the state,” he said. Last year, the Iowa Healthcare Collaborative followed up with a Web-based survey of those 30 safe practices, asking each hospital to complete a detailed self-assessment of how those procedures were being carried out. All but three of the state’s 116 hospitals, or 97 percent, returned the survey.

“Now that we have some measures of what that would be, we have coordinated a discussion among Iowa health-care providers, they’re actually stumbling over each other to help each other improve care,” Evans said.

Reducing the rate at which patients get serious infections while in the hospital is one example of how the Iowa Healthcare Collaborative is making a difference, said Dr. Lisa Veach, an epidemiologist with Iowa Health – Des Moines.

One specific procedure that Iowa Health’s and many other Iowa hospitals have adopted in infection control is to administer an antibiotic just prior to surgery to reduce the rate of post-operative infections.

Because the timing of the antibiotic dose is critical to its effectiveness, “a protocol is put in place to make sure the dose is given when needed, neither too early nor too late,” Veach said.

Preventing just one hospital-borne infection can save $40,000 in additional treatment costs related to lengthier hospitalizations, not to mention the benefits to the patient and family, she said.

“Basically, we’ve seen a nice improvement (in outcomes),” Veach said. “We can definitely say we’ve improved that process, and we know that leads to better outcomes.”

The Collaborative’s primary mission is to use information to improve care, and to create a culture of continual improvement in quality, patient safety and value, Evans said. Along those lines, among the events scheduled later this year by the Collaborative is a forum on introducing lean manufacturing-type concepts into the healthcare environment.

“It’s a flashlight, it isn’t a hammer,” he said. “It illuminates what the opportunities are; it helps us ask the next question. But it still creates the situation where the providers who deliver the care have to conceive of the changes and execute them.”

More information about the Iowa Healthcare Collaborative and the 2005 Iowa Healthcare Report can be accessed at www.ihconline.org.

Process Improvement – Is Automation Always the Best Answer?

“Left to themselves, things tend to go from bad to worse.” – from Murphy’s Laws

"It's getting better…A little better all the time" - from “Getting Better,” Sgt. Pepper's Lonely Hearts Club Band - The Beatles

So which is it? If your organization has a culture of continuous improvement you’re probably singing along with The Beatles. If not, you may be singing the blues. And, even if you are getting better, are you truly getting better all the time and in all the places that you could be?

The pressure to drive down costs and time to delivery has been a constant over most of my career, and probably in yours as well. This has been especially pronounced in the manufacturing sector as start-ups and international competitors have taken advantage of opportunities afforded by new technologies and the global economy. They have attacked cost and delivery to grab a share of market and when quality issues threaten to hold them back they vigorously respond by making marked improvements. Older, established companies who ignored the threat have either shrunk in size or disappeared from the landscape.

Smart, well-managed companies have reacted to this attack by reengineering their manufacturing processes and increased productivity in order to match or beat competitive pricing and delivery. Those who are really smart have also evaluated their engineering and business processes for reengineering opportunities. What they have not done is fall into the automation trap. We’ve all seen and heard promises from companies offering big savings in time and money by using their products (hardware or software) to automate operations. The trap is the temptation to go for what appears to be easy and quick fixes provided by these vendors. What is wrong with this is you 1) run the risk of automating a wasteful operation, 2) improve the operation but not the entire process, 3) potentially miss a cheaper, more elegant solution, and 4) face resistance from employees who perceive this as a move to eliminate their positions.

The terms process and operation are often confused. What is a process? It can be defined as the flow of information or products through a department, group, division or company. More fundamentally, it is the flow of activities from a specified beginning action until a specified end action is reached. Improvement involves reducing the time it takes to reach the end action, improving quality and reducing the footprint required for the complete process. So, what is an operation? This is where people and equipment interact with the flow of information, product or activities in the process. It is a subordinate step in the process but can be considered to be a process itself if it involves multiple steps.

No process remains stable and no process improvement lasts. The Murphy’s Law quoted above applies to all processes. Processes are in one of three states. They are either out of control, under control but in need of improvement or under control with continuous improvement implementations. We have to continually work at keeping processes as lean and waste free as possible. Processes tend to grow longer and more complex over time. One example is that we add more oversight like inspections and sign-offs as quality problems appear in the process, adding more steps where delays and errors can occur.

We tend to overlook many business and non-manufacturing processes that appear to be mundane, traditional or isolated from the bottom line. We do this at great risk. Many business or support processes can be the source of the very bottlenecks that keep engineering and manufacturing processes from being implemented effectively. How could this be? I once worked for a company that had a process for disposing of surplus equipment that typically had little or no book value. This process typically lasted for months, required about 100 approval signatures and generated an incredible amount of paperwork to get rid of a single machine. Over the years several groups tried to reengineer this process, but because it was not a manufacturing process they did not garner management support. All those signatures were required because sometime in the past a machine was disposed of that was deemed by management to still have some useful life left on it. What a waste of time and resources for no appreciable return.

Have you ever heard of the 95/5 rule? Most people haven’t, or if they have, are skeptical that it could apply to any of their processes. It simply states that typical processes consist of 95% non-value adding time and only 5% value adding time. The issue raised with this rule is the definition of value added. Economists and industrial engineers have differing view points on this term.

Wikipedia defines it in an economic way: Value added refers to the additional value created at a particular stage of production or through image and marketing. In modern neoclassical economics, especially in macroeconomics, it refers to the contribution of the factors of production, i.e., land, labor, and capital goods, to raising the value of a product and corresponds to the incomes received by the owners of these factors.

The Six Sigma web site defines value added as: To be a value added action the action must meet all three of the following criteria: a) the customer is willing to pay for this activity, b) it must be done right the first time, c) the action must somehow change the product or service in some manner.

The Six Sigma definition is what we are interested in. In a competitive environment costs that do not contribute to value adding must be reduced to a minimum, not passed on to customers. In order to do this we must eliminate waste. Waste in a process is any activity that does not result in moving the process closer to final output or adding value to final output. There are seven main wastes: overproduction, inventory, waiting, transportation, motion, process (useless steps in a process) and defects.

The Practice of Process Improvement

1. Select a process that, if improved, will have a positive impact on the organization. It could affect finances, quality, delivery, customer satisfaction or a combination of these. The object is not to eliminate people - it is to improve the process so people can be freed up to increase throughput or take on additional business for customer satisfaction.

2. The process must have a clearly defined beginning and end; otherwise the scope will be too broad to accomplish any meaningful objectives. All processes involve steps that are processes in their own right and may be the subject for another improvement project, so you need to stay focused.

3. No process improvement can take place without involvement of a process owner. Who are process owners? They are people who have the most to lose or gain from this process and have authority to lead reengineering the process and to implement recommended changes. Their job, prestige or promotion may be on the line. They must communicate their desire to improve the process and provide support and guidance to the process improvement team.

4. A team has to be organized by the process owner to map the process, reengineer it and implement the new process plan. This team is made up of personnel who represent and are key participants in the operations, internal or external customers and possibly knowledgeable outsiders. They must have authority and time allocated to carry out their task without interference. Many organizations have problems with allocation of time for the team. It has been proven it is always cheaper and faster to allow the team adequate time to complete the project than to meet over and over again in an ad hoc fashion to try and fix process problems. Avoid the temptation of hiring a consultant as a substitute for the team. Nobody knows your processes as well as your own people.

5. The process must be mapped (or diagrammed) as it actually is, not as people think it works or how it was originally designed to work. This is one of the most time consuming parts of the improvement process because it involves breaking the team into smaller teams for interviewing, observing & timing steps in the process. To avoid bias, small teams work in areas that they are not involved in themselves. Often, steps are uncovered that teams or process owners were not aware of. The map is then assembled by the whole team for analysis.

6. After the map is complete the team studies each of the steps with the goal of shortening the process. There is the obvious reason that a shorter process means less cost, but there are other considerations as well. A process with fewer steps means there are fewer chances for things to go wrong and if they do go wrong it is easier and quicker to fix them. Also, a shorter process means results are in customers’ hands sooner.

7. How do we shorten the process? I’ll bet a lot of you said we could automate some of the operations. Well, you’d be mostly wrong. The first thing we want to do is eliminate all non-value adding operations where possible. There are some limitations because we must keep legal and physical requirements in mind. The next thing we want to do is consolidate related operations – especially those in physical proximity to each other. And finally, we want to simplify or automate by looking at remaining operations and evaluate them as processes within the larger process. We automate only when we are sure all waste has been eliminated or minimized. Unfortunately, many organizations spend great sums of money on automating wasteful processes and end up with improvement in one or more operations in the process but with no reduction in overall throughput time.

8. The biggest failures in process improvement are lack of implementation of the redesigned process and reexamination of the process on a regular basis. Just as in sports, follow through is key to success and differentiates pros from amateurs.

There is nothing wrong with automation. Especially when done the right way. Don’t automate wastes in your processes and don’t ignore people issues. Instead, get everyone involved in improving the process and automation will return greater rewards for your investment.

Baxa Corporation’s Jeff Baldwin Honored as a Top Business Leader by the Denver Business Journal

In an awards ceremony held Friday at the Denver Marriott City Center, Baxa President and Chief Operating Officer Jeff Baldwin was recognized as one of the top 40 business and community leaders in the Denver area. The 2006 winners were chosen on three criteria: business leadership, personal accomplishment and community involvement.

Englewood, CO (PRWEB) March 19, 2006 –- Jeff Baldwin, President and COO of Baxa Corporation, has been recognized as one of Denver’s top young and dynamic business leaders by The Denver Business Journal. The annual award is given to the top 40 professionals under 40 years of age who are making an impact in both business and community efforts. Baldwin, along with the other 39 award winners, was honored at a special luncheon ceremony held Friday at the Marriott City Center in Denver.

“Jeff is unique in his balancing of global community support and leadership in operational excellence,” notes Greg Baldwin, Baxa Chief Executive Officer. “He was instrumental in developing the company’s operational strength through the implementation of the disciplines of lean manufacturing and Six Sigma. Currently Baxa Corporation's Chief Operating Officer, Jeff previously served as General Manager of the company's UK subsidiary operations.

Jeff and the other 2006 winners were chosen on three criteria: business leadership, personal accomplishment and community involvement. Baldwin has a history of global community service, beginning with two years as a Peace Corps volunteer in Nepal. He chairs the Stewardship Committee at First Universalist Church of Denver and is currently serving on its Board of Trustees. Jeff’s other community involvement includes support for the local Family Homestead charity, the Bridgeway Home in Lakewood, the Denver Art Museum and Doctors without Borders. Extending his personal philosophies to Baxa, Jeff promoted the idea of providing an annual paid volunteer day for every company associate, giving them the freedom to give back to the charitable organization of their choice.

Jeff’s leadership has had measurable impact on Baxa Corporation as well as its community. Fifteen years after joining Baxa Corporation for a temporary summer position, Jeff has made significant contributions to its worldwide manufacturing excellence. As General Manager of Baxa Ltd. in the UK for example, he led a turnaround of the operations that resulted in cost reductions, sales increases and margin improvements. The subsidiary has consistently reported profitable operations since then.

For more information about the 40 Under 40 competition in Denver go to: http://denver.bizjournals.com/denver/event/1992

Baxa Corporation is a family-owned business based in Englewood, Colorado. Celebrating thirty years of operation in 2005, the company was recognized by both ColoradoBiz magazine and the Colorado Bioscience Association as Top Company for 2005.

Saturday, March 11, 2006

Company Politics And Six Sigma

March 06, 2006

by Peter Peterka

No grouping of human beings is without some amount of politics. Managing deployment of Six Sigma in your organization will unavoidably run into some personal issues and conflict. However, with deft handling of the personal and political issues that come up, along with patience and perseverance, your Six Sigma deployment will not get derailed.

Political factors that can affect a Six Sigma project include personal resistance to change, inflexible company policies, and incompatibility with existing organizational methods and goals. Not surprisingly, all of these factors also affect business processes of any kind. They are not unique to Six Sigma. This is one of Six Sigma's strengths: realistically acknowledging the way politics work in an organization. Six Sigma is not just number crunching. It understands the importance of and encourages the involvement of people throughout and at all levels of the organization working together toward a common goal. Six Sigma encourages planning, communication, and openness about processes, procedures, and information.

Many people see change, any change, as loss—a loss of their power or a loss of the security of the old way of doing things. Thus, people are prone to defend the old way, out of habit and out of unease. They wonder how change will affect them and what exactly happens behind the scenes and if they don't know, become apprehensive. This is a problem that can be overcome through communication. Six Sigma successes require clear and open communication at all levels. Any change in an organization will meet some resistance, either intentional or just from inertia. When management can effectively communicate that it is behind that change and can communicate the positive aspects of the change, resistance and “turf” politics can be countered and overcome.

Another problem is people who disregard the value and power of Six Sigma and consequently, they are reluctant to support Six Sigma projects. To the uninitiated, Six Sigma may appear similar to or simply an evolution of other quality programs. There have been so many quality improvement fads over the years. It is not surprising that people are now a little jaded. Others may see Six Sigma as solely another cost-cutting or productivity enhancement fad. This is a short-sighted view. Six Sigma is neither a fad nor just another quality initiative. It is a “way of life.” It is a multi-level, cyclical movement toward continual process improvement. The quality improvement fads sell themselves as cheap and easy quick fixes. The reality is that there are no quick fixes to significant process improvement. Six Sigma understands that; it is not a simple quick process. However, the right Six Sigma training and information will help people to understand that Six Sigma is significantly different; it is a robust continuous improvement strategy and process.

Once projects are begun, Six Sigma projects can become a battle of wills for control over which strategy, approach, or tool is used. Team meetings can devolve into arguments over which measurement to use, how it will be calculated, which charts will be generated, whether to use DMAIC or DMADV, etc. Six Sigma is not about making things more difficult. It is about using common sense to make things easier. It is certainly about recognizing that there is more than one road to improvement and more than one right answer to a problem.

In overcoming political problems, the leadership of senior management is critical. Successful Six Sigma programs are built on a solid organizational foundation. The organizational structure and system needs to be clearly identified and communicated to the entire organization to successfully implement Six Sigma Quality. Becoming a Six Sigma organization doesn't just happen. Planning and training goes into setting up a successful Six Sigma organization. Employee roles and responsibilities must be established and clearly communicated to all. For many companies successful in Six Sigma, the key factor has been the direct involvement of their top leaders.

Six Sigma is about getting everyone involved. A Six Sigma project forms a team of people who work together to identify problems and develop solutions. Such teams are not isolated teams rearranging the world for everyone else to live in. These teams are serving the organization by employing the skills and tools they have learned to increase quality and reduce defects. Instilling the team concept along with expert training will go a long way toward solving potential political troubles in your organization.

Four Ways to Help Customers Improve Global Processes

This is the first in a series of articles I will write related to global process improvements. As our world becomes increasingly more complex and interconnected at the same time, it becomes imperative to develop processes that work across disciplines, geographies, and our customers’ companies. I think we all would agree that the only reason any of us are in business is because our customers exist. Only by continuing to satisfy them can we look forward to future success and profitability.

I think we also would agree that as the global business climate becomes more complex and interconnected, it is increasingly difficult to satisfy the customer, especially when each has specific needs, challenges, and competitive conditions. That is one of the many reasons why I say, “Thank goodness for process improvement tools such as six sigma and methods that help manage our business in this global environment.” I strongly believe that these tools can help companies build value with customers. If customers are why we are here, making our operations work better is how we serve those customers.

Internally, tools such as these drive improvements across the broad spectrum of business processes and geographies. This translates into a significant competitive advantage, of which we’ve seen proof time and again. If you’ve been successful with business process improvements internally, the next logical step is to bring what you have learned and apply it to your customers’ processes. In the rush to launch process-improvement efforts with customers however, it is important to remain focused on some important criteria.


Understand Customer Processes and Problems

First, customer projects must be designed to address customer pain-points and solve problems generated by a customer process. This should be done using customer-defined metric. For example, a project disguised as “for the customer” that is actually intended to accelerate payment to your own company isn’t a customer project. In fact, the outcome of a project that is truly “for the customer” may actually reduce some of your business with them in a certain area. When customers see improvements that you have helped achieve, their loyalty will likely benefit your company in other ways.


Identify Meaningful Projects

There are several areas to explore for improvement efforts. While quality issues come to mind first, others abound. Supply chain, product performance, manufacturing productivity, safety, and financial or transactional issues are all fertile ground for meaningful and productive customer-improvement projects. It often helps to have a common language for framing issues. The process-improvement tools that have become increasingly widespread in recent years provide that common language and framework.


Introduce Concepts Carefully

As you take these new methodologies to your customers, most of them will not be familiar or experienced with the tools. It is important to ensure that they are properly trained in the concepts. Only when your customers have a strong comfort level with the tools you are asking them to adopt can they buy-in, become engaged, and embrace the concepts and methodology fully.


Help Customers Own the Project and Follow Through

Presented in the proper manner, the customer likely will see benefits in undertaking the project and will value its outcome. Without someone owning the project on the customer side though, it may be destined for certain failure. Therefore, just as with internal projects, it is crucial to have a champion on the customer-side to promote and carry the project through the organization. The higher that person is within the customer’s organization, the better.

Finally, the customer must possess a set of follow-up measures that will maintain the process-improvement momentum for the long-term. It must be their responsibility to implement the improvements and consistently do follow-ups to maintain the gains.


Conclusion

What do we know about the value of global process improvement efforts for customers thus far? Experience has shown two primary benefits: strengthened customer relationships and growth. It is logical that the first would lead to the second. Satisfying our customers is why we are here.

Medicaid Savings of $10 Billion Per Year Possible From Nursing Homes

Thursday March 9, 10:00 am ET

Paradigm Shift Reduces Medicaid Billings, Increases Profits and Improves Patients' Quality of Life

SCHAUMBURG, Ill., March 9 /PRNewswire/ -- Caregiver Management Systems (CMS), a Schaumburg, Illinois based management consulting firm specializing in long-term care, has developed a nursing home care system that has reduced Medicaid billings by over $14 million in 15 years. If the Caregiver Management approach was utilized throughout the nursing home industry, it could save Medicaid $10 billion per year.
This case management system, using W. Edward Deming's principles, Six Sigma tools and ISO 9000 standards, has increased the number of patients returned to health and sent to their own home or an assisted living center per year by over 40%. Using this system in over 100 skilled nursing facilities in the last 15 years, 15,000 patients were discharged and not placed on Medicaid. This compares to an average of just 200 patients per year before CMS implemented its system.

The CMS approach, by paying for outcomes rather than treatment savings, might equate to $10 billion per year in Medicaid savings for skilled nursing care; $40 billion in Medicaid savings in hospitals; $50 billion in Federal and State Medicare and Medicaid administrative costs; $200 billion per year for wasteful business practices of health care providers and vendors; and another $100 billion for wasteful prescriptions, treatments and testing.

The epiphany to change occurred in November 1987. The Chicago area had a snowfall of 16 inches in 24 hours and only half the staff attempted to get to the facility. Jerry Rhoads, CEO of Caregiver Management Systems, overseeing operations of an Illinois nursing home, instructed the Assistant Director of Nursing to organize teams to meet patient needs and forgo the departmental structure. When Mr. Rhoads arrived, there was a different feel and atmosphere at the facility. The staff was on a mission and was not to be deterred. They were focused on the residents, not on busywork. The patients received excellent treatment and the attitude of the staff and patients had never been better. The facility ran better with half the staff and more was accomplished in that three-day period than ever before.

The short and long term benefits were that staff turnover was reduced from 200% to 20% and patients released to their personal homes increased dramatically by over 40%. The intended use of the Medicare law was implemented, reducing Medicaid billings. The change in operational structure converted the nursing home from a warehouse to a carehouse.

Jerry Rhoads stated, "We have complete study summaries available documenting that the current Medicaid billing procedures are often counter productive to the patient's welfare and do not use Medicare as it was created in 1965 -- to help return our senior citizens to productive lives. Changes in current Medicare and Medicaid laws and policies can make a difference. A paradigm shift in the care and management of nursing homes can make an even greater difference in the lives of our senior citizens, their families and the cost to the State and Federal governments.

"The budgets for fiscal year 2006 and 2007 propose to reduce federal funding for Medicaid by $41.6 billion, by annually cutting Medicare by $6.4 billion and cut Medicaid by $4.8 billion, impacting the poorest Americans. States are facing major budget pressures and may be forced to reduce health coverage to the neediest patients. Total health care expenditures are to reach $4 trillion dollars by 2015 and the Federal program is expected to be bankrupt by the year 2018. The CMS management system reduces expenses and Medicaid billings, increases profits and improves patient outcomes."

Caregiver Management Systems, Inc. is a management consulting firm specializing in long-term care. Jerry Rhoads, CPA, FACHCA has over 40 years experience in hospital, nursing home, home health and physician reimbursement and has formed All-American Care Centers.

Preparing the organisation for change

To quote an anonymous author, "Change is inevitable except from a vending machine". Most individuals and organisations do not readily embrace change. Often, they take steps to avoid it. In many cases, individuals expend more energy resisting change, without realising that it would take lesser energy to just change. It is human nature to accept status quo and feel uncomfortable about the unknown state brought on by change. A plethora of research exists on the topic of change and change management. Thousands of consultants are employed because of the inevitable and constant need for effective change management in organisations. And within organisations, effective change agents are desired commodities.

Leadership Commitment for Change

As cited in the previous chapters, leadership commitment for an organisational activity, including change, is a key ingredient to effectively managing an organisation. Leaders must be actively engaged and "walk the talk". Leaders should create or foster a culture, where change, spurned by continuous improvement, is expected, and desired behaviours are rewarded. Leaders also need to assign and support effective change agents within an organisation, and hold key members within the organisation, responsible and accountable for achievement of results and continuous improvement. Status quo should not be tolerated.

The old adage "manage change or change management" cannot be more true. Unfortunately, most organisations and people, don't deal with change particularly well. In addition to leading by example and supporting change within an organisation, leaders need to help create an environment where the need for change is understood by everybody. Sometimes, this is communicated in a crisis mode, such as by an organisation in dire financial straits and about to go out of business. By this time, it is probably too late to change. And the key stakeholders - employees, shareholders, communities, and so forth - will hold the leaders accountable for not having made the necessary changes to keep the organisation viable and successful.

As will be discussed later in this chapter, leaders need to create or reinforce a culture that promotes change. Employees will constantly invoke the "WIIFM" adage —"What's In It For Me?" Leaders, working with their change agents, need to help the entire organisation understand the need for change and the impact it will have on all individuals and parts of the organisation. One way of doing this is by estimating the magnitude for change.

Change agents within an organisation are rare, yet, desired entities. They must effectively implement changes throughout the organisation, knowing that they will face resistance from every quarter. Change agents must serve as extensions of the senior management. The typical attributes, change agents must posses include an ability to get things done by others, respect for and by the organisation, and demonstrated history of achieving results and meeting commitments. Six Sigma Black Belts are taught change management as part of their overall training and make acceptable change agents in most cases. They identify new ways of performing old operations and implement these changes in various parts of an organisation.

Estimating the magnitude for Change

In most organisations, change occurs on a regular basis. However, its magnitude varies, and in many cases, organisations do not notice the changes that have taken place. Most large organisations manage change through period reorganisations or restructuring. Organisations may restructure themselves every 12, 18, 24, or 36 months. Once they change, the new structure and behaviours settle for a period of time while everyone gets accustomed to the new structure. This stepwise approach to change is depicted by the stepping stone line Gradually, the changes become more and more frequent, larger and more radical, or the organisation will become less suited for the business environment. However, since the environment is acknowledged to be changing exponentially, such an approach means the organisation will always lag behind the ideal situation. The employees are sure to be frustrated by the tumultuous, periodic changes.

Perhaps an organisation views the useful life of its technological base as 10 or 15 years, and depreciates and replenishes the technological base accordingly. Perhaps an organisation invests in a week or two of training each year, and relies on it to keep employees "up to speed". Perhaps an organisation relies on the marketing strategy of "milking" mature products rather than rapid product innovation. All of these viws will lead to a constant rate of change of 10 to 15 percent every year. This rate of change is guaranteed to eventually lead to mediocre organisational performance that ensures that the organisation significantly lags behind the business environment.

If the environment is changing exponentially and organisations are changing slowly, in a stepwise or gradual fashion, facing future shock is inevitable. Often, the reality check takes the form of a merger or acquisition. Sometimes, the future shock takes the form of corporate bankruptcy. In some cases, the future shock takes the form of radical downsizing to hang on to one or two "core competencies". And, often, the future shock is marked by a significant decline in stock price with investors losing confidence in an organisation. But if an organisation pursues an appropriate strategy, the future shock may never happen. Change, or expectations for change, can come to an organisation through many different means. Some examples include:

Customer Expectations

Customers are dynamic and always changing. As individuals, we expect new products and services to be better and faster than the previous models or versions. We expect better service and technical support. Our expectations are continually increasing, as new levels of performance become the norm. Consumers do not expect product capability and service to decline. To meet these rising expectations, businesses must continually improve and innovate at a rate, at least, equal to the increase in customer expectations.

Technological Change

The rate of change in technology continues to accelerate. No longer are there "high technology" businesses; all businesses are directly affected by rapid technological change. Customers expect a new personal computer to have a faster processing speed, more memory, higher resolution, and better software. These expectations are uniform across almost all product and service industries. The Internet, has changed the way business and support services are conducted. And there are certain to be big changes in the consumer use of the Internet when web TV becomes more widespread. The only thing certain is that there will be new and currently unavailable technological advances, that will be in widespread use in five years.

According to the survey of CEOs, conducted by the US Department of Commerce, the second most critical issue in North America and Europe was dealing with rapid technological change. This was the most frequently identified issue in Asia. The issue of technological change included both rapid change in products as well as underlying systems. The implication is that functional life cycles have become shorter and shorter. For example, an old 486 computer with a Windows 3.1 operating system may still perform as well as it did in 1995, but it surely has been functionally obsolete for years.

Global Competition

The rate of growth of international trade among industrialised economies has been twice the rate of domestic economic growth for years. The issues that concerns CEOs today are related to globalisation and global competition. According to the survey conducted on behalf of the US Department of Commerce, many CEOs felt that within the next decade, foreign competition would pose a serious threat to their companies. The reason is that customers have a wide array of product and services to choose from. Country of origin of a product is less and less of a concern to customers and is often unknown. In fact, many "foreign" products have a higher domestic value added content than traditional "domestic" products. Customers select from the products of the very best global suppliers, guaranteeing tough, global competition in all major economies.

Never before has it been easier to do business on an international basis. Companies specialised in dealing with customers, tariff, and shipping issue make the process of delivering goods and services to another country possible for organisations of any size. Many marketing plans being put in place today are global in nature. The ease of doing business internationally has spurned global competition in virtually every market segment.

Customisation and Niche Players

Customers are demanding more and more customised products and services, forcing suppliers to produce more customised products that fit a customer's specific needs. This change in customer requirement is forcing organisations to change their productive processes to become more flexible and adaptable. There are many more "niche" markets (and market players) that larger organisations have trouble adapting to. Economic order quantities are not driven by a formula in an economics book; production levels are driven by customer demand that can change quickly.

Implementing Strategic Change. Tools for Transforming an Organization. Steven H Hoisington and SA Vaneswaran. Tata McGraw-Hill Publishing Company limited, New Delhi

Sunday, March 05, 2006

Optimize Your Operations (Doing Nothing is Not an Option)

Author: Fred Fishman
Issue: 3/2006

In the good old days, it seems as though profit margins were high and demand was upward and predictable. While business inefficiency was always a topic of some concern, it was overpowered by the need to never stop the production juggernaut. Where inefficiency was recognized and addressed, the attention was clearly on improving the means of production, not on the business as a whole. The traditional business school rules that governed product and process decisions reliably delivered acceptable profit and growth. So, why change?

Looking back, the certainty of after-the-fact analysis lets us cite many reasons for needed change. How about dramatic increases in global competition, or the explosion in commodity and energy prices to record levels, or the rush to bankruptcy by industry-leading companies struggling under the burden of wage structures and legacy costs casually negotiated during happier times. In retrospect, the old ways are clearly not the long-term answer.

Businesses today must scrutinize every aspect of their operations to determine what really matters, and what doesn't. Continually working to optimize a business – be it manufacturing or service – needs to be embraced. It is embraced by those successfully competing, and winning, on a global scale.

The time-honored premise of workers watching over each other to provide internal checks and balances, of inspectors serving as scorekeepers for knowingly flawed production processes, of measuring a business' success by the size and quantity of its brick and mortar or capital equipment, doesn't cut it any more. Today's measure of business success is a company's ability to rapidly, efficiently and profitably adapt to their customers' changing needs.

The means to this end is determining and embracing best practices that promote lean and agile operations, and stressing customer-paid value-added work instead of traditional paradigm-based feel-good activities.

The words defining success in the new business lexicon include lean, agile, quick, pull, short, straight, clear, simple, clean, at-hand, velocity and value-added. Ironically, today's kiss of death words are often the very same words that used to describe business dominance – inventory, capital-intensity, work-in-process and the like.

To survive and prosper, businesses must determine who in their industry does what best, and how can they implement industry-leading practices that they can improve even further. They must understand their customers and competition like never before, and be able to service their customers better than anyone else. How rapid, simple, straightforward and quickly can their operations be?

Unfortunately, traditional activities can become so tightly woven into the fabric of a business that it becomes difficult, if not impossible, for these businesses to internally recognize the need for change. Intelligent and well-intentioned employees at every level can become protective of their space and function, very often to the detriment of their employer, the company's performance, and its customers.

These employees develop a pattern of work they like to do, typically increasing in volume and complexity over time. Their work is intended to ensure that they remain a critical and irreplaceable part of the process. Often, no one else knows what they actually do as the work is seldom documented, but it seems to be a vital step. Nearly always, this additional effort is non-value-added and simply adds cost to the product without generating value that the customer will pay for. Multiply this added effort generated by a single employee over a large number of employees to fully understand the magnitude and impact of this creeping complexity. Most internal efforts to challenge and remove this added work are unsuccessful, as personalities, tradition, available time, and internal politics hinder any review process.

This paradox of adding layers of non-value work while intending to be more efficient is evident in most businesses. It impacts processes and manufacturing cycles, ultimately separates the efficient from the inefficient, and is the dividing line separating the winners from the losers. The added work ultimately drains the company's bottom line.

This is where the techniques employed by consultants specializing in operational improvement and business simplification can be of great benefit. Whether under the title of Continuous Improvement, lean, kaizen, Six Sigma, value stream mapping, or some other creative combination of these headings, the mission is to objectively assess the flow of the business and remove obstacles to quick and efficient value-added processes.

Regardless of the target, the front office processes in a service business, a complex manufacturing cycle, the routing of order fulfillment through a hospital pharmacy, the interaction of departments within a city government, or the ebb and flow of activity at a call center, a successful consultant (or astute internal facilitator) will quickly separate what matters from what doesn't. They will identify and promote a critical path process that includes what must occur, and specifically exclude what doesn't contribute to a high-value outcome.

Here's the punchline. If your company feels confident that it can perform a critical review of its internal processes that can lead to significant improvement – go do it! If there's any doubt, hire an expert.

Just keep in mind that the do nothing option disappeared with the 5 cent candy bar.

Tyre pressure innovator adapts to save 2.4million pounds

By Colin Holland

LONDON — A company based in Northern Ireland has saved £2.4million over the last three years by improving its business practices with help from Invest NI.

Schrader Electronics, based at Invest NI’s Antrim Technology Park, provides electronics solutions to the automotive industry and is a major supplier of remote tyre pressure monitoring systems.

It signed up for the Business Improvement Agent Programme which enables companies to recruit a dedicated member of staff who can introduce knowledge-led business improvement techniques.

The Business Improvement Agent post is funded jointly by the company and Invest NI for three years. It aims to achieve savings for the company of at least three times the agent’s salary, for each year of the programme.

The Business Improvement Agent at Schrader was Conor Drumm who helped the company to apply a variety of process tools and techniques in four main areas of operation: design, manufacturing, business processes and personnel development.

Drumm said, "We used the Six Sigma methodology to improve design and process performance, and applied lean manufacturing techniques to look at production cycles, increasing efficiency and eliminating waste. Building teams and developing performance indicators for each department has helped embed a culture of continuous improvement right across the company."

During the three years the company saved over seven times the target amount and also doubled its workforce.

• In optimizing automotive CAN and LIN networks, the need to maintain a singular testing/monitoring point where test equipment can look through all different implementations 'in place' is vital. A recent article on Automotive Design Line, Christopher J. Loberg of Tektronix describes how test equipment can optimize intelligent automotive CAN and LIN networks.

Survey shows no change in Six Sigma salaries worldwide

Pay levels for Six Sigma professionals show little change since last year, according to the third annual iSixSigma Global Six Sigma Salary Survey published in the March/April 2006 issue of iSixSigma Magazine.

"We surveyed more than 2,400 people deployed full-time to Six Sigma work - black belts, master black belts, champions and deployment leaders," commented Michael Marx, research manager for iSixSigma Magazine.

According to the survey, Black Belts earned just over $75,000 on average worldwide; average salaries for the other three roles were in the $101,000 to $106,000 range. People reported their salaries in U.S. dollars and there were no adjustments for the cost-of-living in different countries.

"These numbers were up slightly from 2005," said Marx, "but not enough to be statistically significant. Still, it shows that you can make good wages as a Six Sigma professional."

One subgroup that showed a large increase in average salary since last year was champions who had graduate degrees: their salary went up $25,000 on average. Black belts in Latin America and Europe also saw significant increases ($4,000 on average). And in the U.S., black belts and champions with more than 10 years of experience saw significant raises as well. Salaries for all other groups worldwide remained flat.

The survey also explored factors that may contribute to an individual's earning power. "This was the first year we asked people to indicate whether they had official certifications," said Marx. But though certified Black Belts appeared to earn slightly more than their non-certified counterparts, the difference was not significant.

"Globally, experience is a big factor for both the Belts," Marx said. "The longer they've been in the position, the more they make."

Education influences black belt salaries - people with graduate degrees earn significantly more than those with only an undergraduate degree - but the same is not true for master black belts.

There also was a difference in what various industries pay. "If you're a black belt, you'll find the highest average salaries in the IT sectors, advertising/marketing and pharmaceuticals," said Marx. "Master black belts earn the most in healthcare, financial services and aerospace/defense."

The full survey results present both worldwide averages and averages for five geographic groups: the U.S., Canada, Latin America, Europe/Middle East/Africa and Asia/Pacific nations.