DNA - Red Bead Debrief

Debrief of the Red Bead Experiment

WHAT DID YOU SEE?

Best Efforts
Continuation of employment dependant on performance
Threats - there are hundreds of people out there that way your job
Work standards - Quotas
"We understand our business here"
"Management is watching the figures"
POSTERS - What effect do you think the posters have on the outcome?

Why are the procedures so rigid? So there is no variation!!

What emotions do you think the workers experiencing?

The Foreman? (Dr. Deming)
Inspectors?

As the foreman, what do you do to make things BETTER?
What can the workers do?

What can the workers do?
Merit pay & probation?
Numerical goals - individuals?
Threats?
Numerical goals - team?
Threaten plant closure

What effect did all of the foreman's & management's attempts have on the outcome?

What message was sent to the workers?

What are the emotions the worker are experiencing?

What do you predict will happen using only the best workers?

The Process exhibits good Statistical Control, Based on INTIMATE KNOWLEDGE of: Procedures

This is a sample of a constant cause system.
No evidence that tomorrow will be different than today.

All variation attributed to natural variation of the system (common cause)

The worker have put into the job all they had to offer

Example of previous sessions: same beads, same procedures, same paddle, same foreman, - DIFFERENT WORKERS · (stable now - stable in the future - unless something changes)

After a long time the average will settle down to a number - WHAT NUMBER WOULD THAT BE? (if you said 10 - you are wrong ---- A for math, F for business)

What kind of sampling is demonstrated?

Mechanical Sampling NOT Random Sampling!
Schools taught you 'Probability' - NO ONE taught you Sampling
Not the text books - Not the teacher:
they did not know HOW COULD THEY KNOW - THEY NEVER DID IT!

A Lesson in Sampling:

Random Numbers
Frame - Label each bead

A lesson in Sequential vs. independent inspecting
Sequential inspection has less integrity

Story of 11 Proof Readers
Story of Time Cards

What do you know about the BEADS?

Red ones are heavier - 2 white + 2 red coats of paint
How many suppliers of beads? 2?
Which one is producing how many?

CHANGE THE PADDLE - GET DIFFERENT RESULTS

Paddle # 1 - 11.3
Paddle # 2 - 9.6
Paddle # 3 - 9.2
Paddle # 4 - 9.4

Mechanical Sampling does not tell you what is in the LOT!!!

The Difference between 11.3 & 9.2 might put you out of business!

Discussion

What are the effects of the merit system on the number of red beads? What are the supervisor's explanations?

How do the "best" workers' results on Day 5 compare to the results from the previous four days? What conclusion do you draw about the judgment that these are the "best" workers?

Have you had occasions when barriers prevented you from being able to do what you believed should be done in your job?

Have you ever penalized someone whose results were affected by factors they could not influence?

Are there examples of read beads in your organization?

How does one work with a supplier to reduce the proportion of red beads in the incoming material?

What do you know about your systems of measurement? Do they show statistical control?

We must become
the change
we want to see

Mahatma Gandhi