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Portrait of an Agile Manufacturer

I often find that people can learn most effectively by comparing, through analogy, a completely different business, technology, market, industry, etc. Here is an excellent example of a food manufacturing company that has embraced the principles of agility to drive a successful business model in their industry.

What have they done?

"The plant is a model of agile manufacturing, capable of producing a million pounds of food each month. Operations are governed by a 183-step commercialization process that lays out everything from feasibility testing through postlaunch assessment. A half-million-dollar enterprise resource planning system tracks every step in production--more than 2,000 discrete transactions a day--from the arrival of raw ingredients through shipment of final product. The technology also generates new formulas (that is, recipe cards) every time a batch size changes, which helps workers adjust quickly if a customer suddenly doubles its demand for ginger-carrot soup.

Finished products travel into the packaging room, where employees sort them into boxes, bags, cups, or pouches of various sizes. Workers in lab coats collect samples from some of the unsealed containers and analyze them at diminutive lab tables stocked with microwaves, scales, and test tubes. Using computer readouts they check pH and salt levels--but also more aesthetic qualities. Are the tomatoes crushed enough for this particular customer? Is the fondue too clingy or just clingy enough?"

How did they accomplish this?

First of all, much of the factory was designed by the factory workers themselves. Talk about empowered teams! How much do you listen to and provide decision making to your front-line developers and testers? What organizational impediments have been in their way since the beginning of time that "are just the way things are around here."? It may be time to turn the tables and support your teams.

Second, the factory itself changes - from the paneled moveable walls, equipment on wheels, cords and ducts hang from the ceiling, at the end of a shift everything is wheeled to the center of the room and hosed down. Talk about closing out a iteration! When they are done with a shift (iteration?) they are completely done! Developed, Tested, Delivered! Is your environment and infrastructure supportive of your teams completing each iteration and allowing them to be completely done? How configurable is your office environment for creating dynamic, problem-solving teams? Do you have movable walls and desks? Is power hanging from the ceiling so that you can move anywhere? How much wireless internet and phone support have you provided?

Third, they test immediately. Yes, each iteration is completely tested! Possibly if you put your developers and testers in lab coats, they would take on more of a scientific approach to the solutions they created. Every item that is created in a manufacturing environment must be inspected. Positive and negative results are immediately fed back into the process to alter the solution. How often is your team inspecting its own solutions? Are the results published daily?

I hope this manufacturing example will help you see some of the deficiencies in your current development process. I know it has given me a new picture of adaptability and possibility.

 

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petebehrens (Pete Behrens) : @Armond_M sorry, no recording of my Leading Agility "Inside-Out" from #RallyOn2012. Will look for a future recording opportunity.

petebehrens (Pete Behrens) : (time lapse) I DID IT! I ran a 44:30 10k - on a flat sea-level course in Seattle in cool weather. Mile high #BolderBoulder next.

petebehrens (Pete Behrens) : Amazing - 5:20am in Seattle hotel, all 9 treadmills are busy. Good motivation to run outdoors today.

Armond_M (Armond Mehrabian) : @petebehrens Thanks for sharing the slides. Is there a webinar-like presentation of these slides somewhere? #RallyON2012