According to its jacket,
Working Smart, by Slaughter and Parker, is a "Union Guide to Participation Programs and Reengineering". This book is only of value to dyed-in-the-wool union activists; there is little or nothing here for either workers and little for people interested in state-of-the-art manufacturing practices. I am careful to distinguish between unionists and workers, since their objectives are not always the same: crisis and antagonism pay for union activists, but nobody likes to work in that environment. The authors also seem to be careful to make the distinction: after all, it is not a "Workers' Guide". (
I'm no fire-breathing anti-unionist, either)
Working Smart is a fun-house view of lean manufacturing. There is a rough 1:1 correspondence to the actual theory in much the same way as any good parody approaches its target. The phrase "management-by-stress" is frequently (but not always) used in place of "lean" or any number of other, related, or similar theories. This is a cheap rhetorical trick that mostly gets in the way of meaningful discourse. They use other such tricks, such as referring to the removal of wasteful motion as "speedup" as if improving an operation was in any way similar to increasing the speed of the assembly line, especially in an operation where the assembly line is intentionally run at a fixed rate (the
takt time) dictated by consumer demand. Learning new skills is called "deskilling" because it creates generalists rather than specialists.
I would also point out that although there is little here for people interested in lean and related practices and theories, they do make a strong point about safety. Bill Waddell has
pointed this problem out and noted that Toyota has a long ways to go to catch GM on the safety and repetitive motion injury measure, so it isn't as if the lean consulting community is unaware of the problem. Unfortunately, those points are mostly constrained to the automotive industry, so it isn't clear that the point carries beyond that industry. At the same time as Toyota grapples with that issue, it should be noted that most lean practitioners recognize injury as another form of waste. To that end, Womack
et al describe in
Lean Thinking the case of FNGP of Michigan, where productivity increased over 1000% (10-fold) at the same time their "OSHA reportable accidents and Workers' Compensation costs both declined by more than 92%." Health issues impact the bottom line. Indeed, some lean consultants have suggested that the GAAP accounting practices be scrapped and replaced with something that counts worker education and skill (human capital) as an asset to put some meaning to the oft-repeated catch-phrase, "Our workers are our greatest asset".
Most of
Working Smart is illogical and contradictory.
- Sometimes they complain about uselessness and even evil of teamwork, other times they complain that management doesn't let them participate in interesting and challenging teamwork activities often enough. On one hand, they claim that everyone is taught about teamwork, but then complain that it is never applied after that initial phase because management has already determined work procedures. At other times, they say that participation in teams results in sharing work secrets with management at the peril of your own job. Which is it: management isn't interested in your opinion or management learns too much from your participation, teams never meet or they are used to extract information? Incidentally, the preference that management set the system up at the beginning with strict work rules is one of the essences of Taylorism, which is alternately denigrated and embraced, as I will discuss in detail below.
- Management is simultaneously stupid (with such gems as "Management is notorious for being unable to see past the end of its collective nose") and so incredibly devious that they can formulate fantastically convoluted mechanisms by which to cheat workers out of money, time, and health without anyone noticing their real goal - workforce domination for the fun of it. Or is it workforce elimination? A friend of mine summarized this kind of thinking by saying that some people believe that management would spend $1 to screw someone out of $0.10.
- NAFTA is evil because, as they say, "no one argues that American workers can compete with Mexican wage levels", but later, "U. S. workers are a bargain, compared to those other developed nations". So which is it: competition with Mexico works against US workers, or against Mexican workers?
- Monopoly is bad, except when you are talking about union workers, and then it is "taking labor out of competition". Competition, it seems, is bad between workers. Unless you're talking about nonunion or foreign workers, in which case see above.
- At one point, Parker and Slaughter tell a story about how workers are given training to do time & motion studies and then ridicule the use of such "experts", but at other times they themselves engage in social and psychological analysis (claiming, without support, that certain tests have cultural bias), critiques of management theory, critiques of design engineering, and critiques of quality control theory with even less apparent training then management gave them on time and motion studies.
- They ridicule the application of Deming's definition of quality by pointing out that the consistent McDonald's product would be quality (it is, if you understand the goal is to produce a reliably consistent product no matter where in the world it is, and millions of people seem to agree), but later they use the same definition to defend the Fiero ("[GM Plant managers] were celebrating what was then the highest weekly quality rating in GM's history - 138 out of 145"). Nobody, but nobody, ever believed the Fiero was a quality vehicle. After all, it had a Pontiac logo on it.
- Their heavily distorted "history" makes Howard Zinn look like a clear-eyed scientist in search of truth: apparently, the deregulation signed by Carter was Reagan's fault, they apparently have never heard that Davis-Bacon and Jim Crow laws were laws and not corporate policies, and government regulatory agencies like the CAB and ICC were not exactly unfriendly to the industries they regulated.
- They routinely assert that workers should stand up for their "rights" when they mean "privileges of seniority in a closed union shop".
- In the good old days of unionization (as they put it, from the end of WWII to the 1970s, or roughly the period in which Sloanism dominated), "Unions won the ability to set standard wages and benefits in unionized industries. In return, unions gave the employers the right to control the organization of work, to introduce technology, to change the product, and to accumulate capital through growing profits." Damn nice of them to give management something to do, and also damn nice of whichever God deposited a fully developed industry over whose output they could bargain. But elsewhere in the book, management is overstepping its bounds by setting up the organization of work without consulting teams, introducing technology to lay people off, changing the product to make it easier to manufacture, and (gasp) accumulating profits.
The most egregious error in the book is that the examples of "lean" enterprises are NUMMI, GM, Saturn, a Mazda plant funded by the State of Michigan, USPS, The Health Care System, universities, and some Baby Bells. Of all of those, the only one even close is NUMMI; the rest were probably chosen not because they were advanced lean practitioners, but because they were unionized. Bill Waddell refuses to have anything to do with publicly traded companies like GM and the Baby Bells because they have all adopted the Sloan/DuPont/Brown management principles by way of GAAP (another topic I will discuss in detail below). And let's be honest: citing the United States Postal Service or the byzantine private/public mess called the "health care system" as an example of lean management is just as nearly either ignorant or dishonest as one can be, almost as bad as citing Bill Clinton (a career politician), Robert Reich (a career academic and politician), Lee Iacocca (a political entrepreneur), and Lane Kirkland (a union boss) as "gurus of competitiveness" (as they call them) and citing Clinton's Council on Competitiveness and Paul Krugman as "reengineering gurus" who use "macho and violent" imagery (yeah, really - it's in there!).
One result of this error is that they talk repeatedly of how management uses lean processes and reengineering to make it easier to outsource and introduce automation, yet these are the diametric opposite of what Toyota does. Toyota is famously conservative about the introduction of technology. By outsourcing, Parker and Slaughter mean forcing single supplier systems to stock parts for Just-In-Time pull, but Toyota keeps dual suppliers and works with them to introduce real JIT methods into their operations. As a result, many Toyota First-Tier suppliers have
expanded their business by supplying to Toyota's competitors, while GM, Ford, Delphi, and all the rest of the Sloanist, GAAP, Taylorist producers keep laying off, outsourcing, and automating their way to oblivion. Only about 12 pages out of 315 are occupied with Japanese companies, but Japan itself is not universally lean as they imply - Toyota stands out even there.
TaylorismSlaughter and Parker exhibit a complete lack of understanding what Taylorism is, or what is wrong with it. They speak disparagingly of Taylorism by way of claiming that lean is "super-Taylorism". To them, the essence of Taylorism is the time study, the use of a stopwatch and experimentation to find the "one best way". To students of Taylor, however, Taylor's theory of Scientific Management only partly depended on the time study. If time study was the only thing ever advocated by Taylor, we would likely have never heard of him since it was merely an application of common sense and the most obvious tool to the problem of high volume manufacturing. Taylor placed much more emphasis on clear delineation between workers and management (managers think, workers do), and between different functions of management. The first is evidenced by this quote from
Principles of Scientific Management:
Now one of the very first requirements for a man who is fit to handle pig iron as a regular occupation is that he shall be so stupid and so phlegmatic that he more nearly resembles in his mental make-up the ox than any other type.
Taylor's devotion to Division of Labor is due to his overweening application of the principle that he gleaned from Adam Smith's description in Wealth of Nations. After "scientifically" determining the exact division, though, Taylor permanently fixed the job classifications. He advocated departmentalization, rigid work rules, and rigid job descriptions.
But that is exactly what Slaughter and Parker advocate: rigid work rules, rigid work classifications, bureaucratization. They ridicule the training of workers as time study engineers, preferring instead Taylor's system of industrial engineers who have to petition the union for permission to do time studies. They deride workers who participate in team activities as "apple polishers", an implication of collusion with "the enemy" and another recurring rhetorical trick. They protest shopfloor communication and the blurring of distinctions between jobs (they point out that "A [desirable] relaxed attitude - 'I am just doing my job, I don't need to pay attention to anyone else's job' - makes the [lean] system inoperable"). They protest the blurring of job categories as "deskilling" as if learning to do more than one job requires less skill. They protest the blurring of the distinction between management and labor on the basis that team leaders should only participate in "management activities" and not in the actual work. When disputing the claims that management and labor have common goals, their adoption of class warfare rhetoric might make sense if they were distinguishing between owners and workers, but the modern, publicly traded corporation is run by hired management. The real distinction between that hired management and hired labor cannot be one of class; it is rather the arbitrary distinction given to it by Frederick Winslow Taylor.
[Aside: By maintaining strict classifications and rules and resisting team problem solving, workers are able to hide aspects of their job and thereby maintain a bargaining chip.
Kaizen encourages them to reveal this secret knowledge, making it easier to document those secrets, eliminate custom work, and train new workers. This is interesting from a transaction cost economics POV, as it illustrates on one hand a principal-agent problem, and on the other hand the difficulty of making contracts in the presence of opportunistic behavior.]
Sloanism and GAAPThe second problem Slaughter and Parker run into is a result of their acculturation in the GM system, where the Taylorism is codified by Sloanism. Waddell and Bodek persuasively argue in
Rebirth of American Industry that GM and companies based on its management principles will never fully grasp or be able to apply lean management theories because of the accounting rules they use. In Rebirth, the single most valuable point is that a company's accounting system sets their definition of profitability, and that everything else about the company flows from that definition. The Sloan system was largely based on DuPont's view of the operation and Brown's implementation of an accounting system based on DuPont's opinion.
To put it in perspective, it is valuable to compare the original Ford and the Toyoda family values to the GM values. Henry Ford and Kiichiro Toyoda both owned a manufacturing concern and made money by manufacturing things. DuPont owned a group of companies that manufactured things, but he had two options for making money: he could manufacture things or he could break the organization up and sell it off by piece. Therefore, he and Brown devised a system designed always to be ready to sell off.
In their system, multiple divisions were organized in the "M Form" corporation in which each division was independently evaluated as a cost center. They looked at it as "islands of cost awash in a sea of profit". Each division "sold" its product to other divisions (for example, Fisher "sold" bodies to the assembly plants). When you take in inventory, that's an asset; when you produce it and make it the next division's inventory, that's a profit; everything in between is a cost. Further, cost is divided into two categories: fixed and variable. The fixed cost is the cost of management and the plant operating costs. The variable cost is the labor. If a plant has high variable costs and little profit, it can and should be sold off in the Sloan/DuPont/Brown system. That system was ascendant in the 1950s, when GM was the mother of all corporations in the post-WWII era, and the structure was embodied in the Generally Accepted Accounting Practices (GAAP) which is today accepted by all publicly traded stock companies. In other words, if you don't follow those practices, you open yourself to civil and criminal procedures by shareholders suits, criminal prosecutors, the SEC, and the IRS.
So it should be no surprise that when union activists look at GM's application of lean theories they find a facade and little else. The accounting system in place in almost all public companies will force them to the same conclusion: eliminate labor because it is a cost, don't worry about inventory because it is an asset. GE took this to its logical limit: keep the name, sell off the manufacturing capability, put all of your effort into marketing and financing. The result today is that GMAC and GE Capital are the most profitable divisions of those companies. The MBAs in charge were baptized in the GAAP and Sloanist M-Form corporation theory; they eliminate variable costs (labor) by investing in specialized automation or by outsourcing it.
And Toyota is beating the crap out of them with people and relatively low-tech, general application machinery.
Quality ControlSlaughter and Parker also demonstrate a complete lack of comprehension of what is meant by quality. Their preferred definition is, "A degree or level of excellence". It is completely resistant to quantitative analysis. What degree? What level? At what price? If it has
any degree or level, it meets their definition. Is the Mercedes 560 SEL a quality auto? The Honda CVCC? Although their prices are radically different, consumers would agree that each was a quality vehicle, but at different prices. Would the CVCC be considered quality at the Mercedes price? No.
They put that in opposition to the standard definitions from Crosby and Deming which both come to nearly the same thing: conformance to requirements or reduction in variation. Slaughter and Parker ridicule that because the specification may be bad. According to whom? The customer? Then the specification is bad and should be changed, which Crosby and Deming both note. That this aspect of both writers' theories is intentionally neglected by Slaughter and Parker is either indicative of their ignorance or a deliberate attempt to imply that Crosby and Deming were too stupid to realize what might happen if you made something perfectly which nobody wants to buy.
But if the specification is good, how do you know if you are delivering it? This is the critical question which is never, ever addressed in Working Smart, and in fact problems with that oversight surface several times. They cite an example from Crosby's
Quality is Free in which the fictional managers take their drawings to an outside machine shop to see if the parts can be made there. When they can't, the managers realize their drawings are wrong, and that the only reason anything was getting out the door was that their in-house machinists were custom-fitting everything together. Rather than note the obvious problems, Slaughter and Parker marvel over the fact that Crosby's fictional managers realize that they don't control the design (recall that Slaughter and Parker imply that this is one of the few things that management should control, if even that). They think that the plant ought to congratulate the workers on their superior skill instead of fixing the problem.
For people inexperienced with actual manufacturing, it might help to illustrate why they are wrong, and not even just by a little. Say you have three parts in an assembly. In the design, the parts fit together perfectly. In practice, the parts don't fit together because of errors in the prints, wearing tools, wearing dies, change in heat treatment or painting, etc. After individual part fabrication, final assemblers put them together, but since they don't fit they have to be adjusted (at additional, unplanned time and cost). One assembler files A to fit, one B, and another C. They make the assemblies work, but filing B may seriously compromise the strength of the assembly and subject it to early failure (nobody thinks to measure this because the people concerned with designing, building, manufacturing, and marketing are all compartmentalized). Furthermore, repair parts will never fit into the assembly consistently because no two assemblies are alike, even if all of the repair parts are (which is, by now, to be doubted). The
Working Smart point of view is that the filing is great and demonstrates the skill of the workers, though they inexplicably forget to question the skill of the design engineers as in other places in the book; they never address the additional costs; and they completely overlook the impact on product life and perceived value by consumers, which they otherwise always go out of their way to blame on management. Perhaps, as people who probably buy into the
Broken Window Fallacy, they figure that if they put out defective units, consumers will have to buy more, thus helping the employment of union workers at plants where this is actually the business plan. This is a result of the GM assembly theory: make a lot of them real fast to keep the unit labor costs down, count the finished but defective products as inventory (assets), and then fix the problems afterwards. Then marvel at the way Toyota takes market share, blame the pension plan, sell off Delphi, lay off 10,000 more workers.
Norm Bodek tells in
Rebirth about an experience he had on a GM line: an inspector was going through a stack of doors to see if they met spec. They had been batch produced into stock (the system preferred by Slaughter and Parker to increase slack time), and he asked how many would be out of spec after the one he was inspecting. "Oh, maybe a thousand or so," came the answer. He asked what would be done about the problem - would it be corrected? "I would notify the die press people to make the necessary adjustments on future doors to correct the problem; then the new doors stamped would meet the exact specifications." He asked about the doors already stamped. "They are normally not too bad, not that much out of sync. When they get to the assembly line the worst thing they might do is use a rubber hammer to make them fit properly into the car." Think about that the next time you buy a product that isn't "too bad, not that much out of sync." Hey, maybe the door doesn't shut right, so maybe you need to use a rubber hammer to adjust it. Still, at least the car has "a degree or level of excellence", even if that degree or level is not very high. While you're doing that, and marveling at the skill of the workers as Slaughter & Parker would have you do, also marvel at the toll on a worker's wrists as he does this a thousand times a day. No wonder they need breaks, huh? And just in case you think I'm just being flippant about that, I actually met a Harley-Davidson engineer back when Harley was coming back from the old every-sled-comes-with-its-own-oil-drip-rag days who told me he had only about 2 or 3 guys who could manually adjust shafts with a hammer, and they were all developing repetitive motion injuries.
But it isn't just Bodek that finds such bizarre notions of work and quality. Slaughter and Parker explain their preferred version of a good job when quoting a NUMMI employee who used to work at the GM plant at that location:
The best job [at the GM plant] used to be material handling. Because what did you do when you walked in the morning. [sic] The first thing you do ... is stop at the newspaper stand and pick up a paper, right? Then you get on your truck and you scout the line and you look for a place to stack material. And you put on eight hours, 16 hours, if you could put on 16 days of material you would do it -- because what's the next thing you do when you stack the line? You went to the satellite area, got a coffee, and you read your newspaper and you didn't have to do anything anymore.
What does this [NUMMI] plant do? Every 60 minutes we are stocking the line. The people who are in material handling now -- they are working eight hours a day.
Relaxation time is the goal of the Slaughter and Parker system, so inventory is preferred and overstaffing is the goal. They have completely bought into the Sloan/Taylor theories of management. I wouldn't count on getting much of a
flow experience from working there. Slaughter and Parker relate this story as an example of how mean the NUMMI management was. The lesson you are to take from this is that the GM/UAW way of doing things was to stockpile WIP everywhere so people could
get paid to read papers work in a low stress environment. Now, how was it fair that some people got this easy job and others didn't? Well, if you are either senior or connected in the union, it is your right. Those mean bastards that took over, they thought that maybe it was a good idea to only produce what was needed in order to eliminate waste, uncover defects before thousands of defective copies were made, to cut the amount of time required to deliver an order without requiring expediters and speedup and overtime, and to actually get eight hours of work from everyone for eight hours of pay. The horror, the horror.
But to return to our three workers and the three piece assembly, by measuring, we may find that there is a continuum rather than a simple binary distribution of "obviously defective" and "obviously usable". Over time, we may find that the arbitrary tolerance threshold between pass and fail is either too tight (we are going to unneeded expense to get within tolerance) or too loose (parts may be usable, but wear quickly and give our products a reputation as unreliable). The
Working Smart way of dealing with this problem is ... well, they never address or even acknowledge the problem, an indication of how woefully uninformed the
Working Smart authors are about quality control theory (though that doesn't stop them from criticizing it). They live in a world where a product either has quality or doesn't. Sometimes they imply that quality is designed in, or that workers fix the design flaws on the fly. Whichever it is, it is inexplicable and amorphous, like pornography for Potter Stewart. They apparently never realize that it cannot be both "designed in" and "fixed on the fly" simultaneously; the two are mutually exclusive. Yet that is how they would achieve quality if allowed to run things. Or fail to achieve it. But what would you expect when the principle critics of lean have been brought up in the culture of GM and the UAW?
SummaryThere is a side point about downsizing and lean. Parker and Slaughter imply throughout the book that the goal of lean is to reduce the number of people required so they can be laid off, which of course is always the goal when applying the Sloanist principles implicit in GAAP. Had the authors looked for counterexamples, though, they might have made a case for a different management approach that workers reading their book might have found useful and interesting. But since their purpose is to introduce
FUD, they were never going to look for or find counterexamples. It is possible, despite what you might think after having read this book, that a manufacturer might take the people freed up from the efficiency improvements in one production line and create another and expand output. They might even
have to do so because the new efficiency may allow them to drop their prices and increase market share.
Lean Thinking cites the example of a unionized bumper manufacturer subcontractor to Toyota in North America - oops, I can see why Parker and Slaughter wouldn't want to discuss that - that expanded their output and payroll dramatically. Toyota is expanding market share and employment while GM and Ford (the anti-lean) are shrinking - oops, let's not face that fact, either. Nowhere in the book do they talk with employees from Toyota's nonunion plants in North America. And what about Wiremold, Danaher, Pratt & Whitney, etc.? Examples abound of how they did more with fewer, and then used the workers freed up to
expand business and in fact increase their pay. [Aside - My criticism of Womack, Jones, et al, is that they imply that everyone can have the same results, but if everyone applied it,
everyone could not expand market share. Slaughter and Parker raise this point in exactly one sentence, from what I can remember.]
The result is that
Working Smart is a one-sided, distorted, childish view of the theories underlying lean and related manufacturing techniques. By avoiding any mention of companies whose adoption of lean has improved the lives of workers, i.e. by choosing only those industries where lean has worked in spite of or perhaps to the detriment of the union hierarchy (the union hierarchy, not the laborers themselves), they cheat their readers out of the opportunity to learn about something they might like to experience. This is a book whose sole purpose is to undermine any attempts by a manager or management to introduce or sustain a culture of innovation or teamwork. It is argumentative (it even features a chapter in which they point out the inconsistencies between, say, Crosby and Deming as if any branch of organizational theory must be completely consistent), it encourages the worst of unionism (featherbedding, rigid work rules, and classifications to thwart management), and it encourages deliberate troublemaking for no other purpose than to make trouble and maintain an environment of conflict.
[Another aside - Kevin Carson
sees it differently. I respect Kevin's take on this. I believe that lean is amoral: it can be used for good or bad, e.g. GM probably has found a system for eliminating more jobs. And we certainly have seen lots of people use the slogans without getting the message. But I also believe that it is potentially valuable, especially as lean is exactly the type of system Kirkpatrick Sale tries to describe as a means for producing goods locally from generalized machinery as discussed
here and it is exactly what Amory Lovins and Paul Hawken see as the productive mechanism in
Natural Capitalism, which I reviewed
here.]
Labels: book, unions