Joe Vorih24:02
Well, the first thing is, when you're running a part of a business, and then running the business, and then you're running a platform of businesses and a group, your scope is a bit different. I was actually running part of the business, all the international operations. So I had a plant in Italy that had lost money for 10 years and they used to send cash, and had a plant in India that had caused a $10 million warranty at the time and was losing money. And then my CEO had called me up and said, 'Hey, listen, it's really great you're joining. By the way, you got to go over there and fix that problem.' Then he called me three weeks later says, 'Oh yeah, you got to go there, I think that might be your bigger priority.' Then three weeks after that he called up and said, 'Yeah, and Cummins, one of our biggest customers, decided they want to start a plant in China and they'd like us to start a plant in China, so that'll be yours too.' So for me, because that was my scope, I went and looked at these two particular plants that already existed were having a ton of trouble, and that was okay. We need to fix the problem. So what do you do? You use the tools you have. And I remember really clearly when I got to Italy the first time and walked around, the plant was not a great plant, but there were good people, they had good products, they were trying to do a good job, but it had been underinvested, neglected, and there wasn't any kind of lean thinking there. And they wanted to invest $2 million in a brand new cell to increase the capacity for their key customer. Let's go take a look, let's go to gemba, let's go look at the cell. So we walked around the cell and there were a couple of machines sitting in the middle of the cell not running. 'What's with these machines?' 'Oh, those are dead.' But they're in the cell, the operators are walking around. We did a little bit of analysis, what do you need? We tried to get the basics of takt time. They needed to have a 25% increase in capacity. We just sat there and watched the cell for about an hour, and it was pretty clear right up front that the actual cycle times and the work that was being done could accommodate that. So I said, 'Tell you what, I'm going to come back in two weeks and I'm going to bring a lean person.' I found a lean sensei, and he came over and I kind of kicked off with him. The managing director at the time wasn't really interested, didn't understand. But we just got to fix this. 'Tell you what, at the end of this week, if we can't fix this problem, I'll sign off the capital request for the $2 million. But if we fix this problem, then we're going to do it this way instead.' By the end of the week, they had relaid out the cell, gotten the dead machines out, balanced the workload in the cell, figured out they could get it done with three operators instead of four, and they didn't need any capital except they needed about $100,000 to redo one or two machines just to make the operations all simpler. So that sounds good. They simulated it, they had actually gotten the first and the third operator kind of job working in the work balance, but the one in the middle was tough. There was a transition in there and it was difficult. The sensei said, 'I really think it'd be great if one of you could run that operation.' I'm the VP of Global Operations. 'If one of you could run the operation, I think it'd go a long way towards showing the operators that you guys care and it'll work.' The operations director didn't want to do it, the managing director didn't want to do it, so I did it. I said, 'Well, take me.' We went down to the tool crib, I got a standard t-shirt from the operators, put my jeans on, and I ran that cell. I ran the middle job of that cell for about three hours until I hit the takt time. And for the next six years that I had that responsibility at that plant, the guy who did that operation used to come out beaming to me every single time I walked by that cell and show me the progress they had made. It was one of those things where you just have to be willing as a leader to get your hands dirty and show how it works. So for me, that was a real key.
Breakthrough because this is, you know, Italy's not an easy place to make these kinds of changes. I had the advantage of speaking Italian, of course, but still we made progress pretty quickly.