Henry Towers, Author at Towers of Quality https://towersofquality.com/author/htauthor-com/ Mon, 03 Jan 2022 04:22:28 +0000 en-US hourly 1 https://wordpress.org/?v=6.5.3 Successful Quality Professionals Make Good Pie https://towersofquality.com/successful-quality-professionals-make-good-pie/?utm_source=rss&utm_medium=rss&utm_campaign=successful-quality-professionals-make-good-pie Mon, 03 Jan 2022 04:09:52 +0000 https://towersofquality.com/?p=7248 I make a pretty good pumpkin pie. The first time, about 30 years ago, I gingerly followed an untested a recipe. The filling seemed too runny, but I trusted the...

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I make a pretty good pumpkin pie.

The first time, about 30 years ago, I gingerly followed an untested a recipe. The filling seemed too runny, but I trusted the method and it actually became a solid, as advertised. My confidence in the system grew as a result.

Over time, I started making slight adjustments based on my preferences and ingredient availability. For example, I found that blending the ingredients smooth, though not recommended, suits my taste better. Adding ginger and holding cloves was another improvement.

Accommodating specific needs while still making a dish that pleased me required further adjustments. I now make dairy-free and gluten-free variations.

I knew I was on to something when someone very dear to me, who professed to dislike pumping pie, devoured mine, eventually saying ‘Your pumpkin pie is my favorite.’

Following a recipe allowed me to benefit from the knowledge of accomplished chefs whom I never met. My own experience alone would not have led to success.

Similarly, it is often the case that those of us who are tasked with implementing our organization’s quality management system (QMS) are not fully equipped for the job.

A talented, experienced quality professional familiar with the work of legendary quality gurus is fully equipped to put together an effective QMS on her own.

The rest of us learned along the way, with spotty, fragmentary training and experience. Maybe we learned Crosby, but not Deming. Maybe we worked in a very structured setting, where we lacked a holistic view of the system. How to create a QMS from scratch?

We need a recipe!

In such situations, ISO 9001 can be the very recipe we need.

In it, we see direct or indirect influences from Quality’s ‘great chefs’: Deming’s PDCA cycle, Juran’s understanding of quality management, echoes of Crosby’s absolutes of quality in the use of the term ‘conformity of products and services.’

To be sure, ISO 9001 fells like a word salad to most first-time readers. Good training by an instructor with real-world experience is indispensable. Still, actionable direction may seem fuzzy at first.

This is the time to trust and persist. At first, simply try to fulfill the standard’s requirements, more or less blindly. Gradually, the all-important ‘why’ of things comes into view.

The pie filling hardens, and product conformity becomes more commonplace. Before long, the compliments start pouring in.

Your confidence grows with your understanding, and you start adjusting the system to better suit your needs. Eventually, the QMS becomes your own.

By the way, if you are curious about my pumpkin pie recipe, just ask: htowers@towersofquality.com.

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Organizational Knowledge – Tribal knowledge by another name https://towersofquality.com/organizational-knowledge-tribal-knowledge/?utm_source=rss&utm_medium=rss&utm_campaign=organizational-knowledge-tribal-knowledge Thu, 30 Apr 2020 18:56:08 +0000 https://towersofquality.com/index.php/2020/04/30/audit-traps-and-how-to-avoid-them-copy/ We Are Special “I get what you are saying, but we are different. What we do is more art than science. I can’t just write a recipe and have my...

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We Are Special

“I get what you are saying, but we are different. What we do is more art than science. I can’t just write a recipe and have my people follow it. It takes years to learn what we do.”
Ah, tribal knowledge…
Most organizations believe that some crucial element of what they do is unique to them. They will say “You can hire someone off the streets to do this, that and the other thing, but what we do, well, that’s different.”
Their secret sauce is what makes them successful, and it is difficult to document. This difficulty is often mistaken for an impossibility.

The Star Employee

As a result, organizations end up depending on a few key, long-term employees who made all the necessary mistakes years ago and now can consistently do the job just right.  These artists are unable to articulate explicitly just what leads to a successful outcome.
Over the years, there may have been failed attempts to formalize the process. Eventually, this was accepted, the process was called an art and not a science, and life went on.
The key employee (let’s call her Jane) is very dependable and dedicated. She is always there, always on time, and she can be counted on to get a consistently good result. When she (very rarely!) goes on vacation to visit her out-of-state relatives, the company arranges the schedule so that her process can wait until her return. It’s a good arrangement and everyone is happy.
But now Jane has just announced that she will be retiring next year. Oops! What to do? In the end the organization decides to hire Bob to shadow Jane and learn from her on the job. There is a big sigh of relief and life goes on (again).

The Dreaded Third-Party Audit…

Then, one sunny July afternoon about a year after Jane’s retirement, a friendly third-party auditor asks to see objective evidence of competence for employees doing critical work, a list naturally headed by Bob.
The management representative explains how this particular process was never documented; Bob only received on-the-job training and there is no objective evidence that Bob did, in fact, learn what Jane attempted to teach him. This, regrettably, is a classic nonconformity. Why?

…And the Inevitable Nonconformity

Under clause 7.2, ISO 9001:2015 requires organizations to identify what skills people need to have, make sure they have them, provide training as needed, and ensure the training is effective (“…take actions to acquire the necessary competence, and evaluate the effectiveness of the actions taken…”). There is also a requirement to keep records of all this (“The organization shall … retain appropriate documented information as evidence of competence.”).
This is when the auditor often gets an answer like the opening paragraph of this blog.

Organizational? Tribal!

Clause 7.1.6 is titled “Organizational Knowledge,” which is defined as “…knowledge specific to the organization … generally gained by experience…” that can be based on “…lessons learned from failures and successful projects; capturing and sharing undocumented knowledge and experience…”
Yup, what the Standard calls ‘organizational knowledge’ is pretty much what we understand as ‘tribal knowledge.’
By definition, tribal (…err, ‘organizational’) knowledge is crucial to the organization. Wouldn’t you want to preserve it and retain it? Of course you would, and the standard does not require an organization to do any more than what it should want to anyway.  But how?

What to Do, What to Do?

While each organization must find its own way, perhaps the simplest goes something like this:

Prepare a matrix were the columns are skills and the rows are employees. Not every employee needs every skill, so place an X or gray out the unnecessary cells. For the rest, use a letter, number or color code that indicates the current proficiency level for each employee/skill combination. For instance, 0 could mean “not yet competent” and 4 could be “master level – able to train others.”
Next, make sure that every employee has achieved at least the minimum level of competence in each required skill. Provide training as necessary, and verify that the training was effective.
Make sure to keep evidence of competence for each employee on each relevant skill. A signed attendance sheet is good evidence of training, provided it lists the subject, instructor, date and length of the course. Effectiveness can be verified with a quiz, a statement from the instructor, or witnessing.
Review this matrix often. Use it to uncover single points of failure (like Jane), plan employee training, decide who is ready for a transfer or promotion, etc.
Tribal knowledge, as one type of competence, is not exempt from these requirements. On-the-job training is a perfectly acceptable way to “acquire the necessary competence,” so long as there is a record of this training, and training effectiveness is verified.
 A statement signed by a valid subject matter expert (like Jane) indicating that she witnessed the trainee perform the process satisfactorily can provide the necessary evidence of effectiveness.

Following these simple steps will keep you in the good graces of pesky third-party auditors. Much more importantly, it will go a long way to ensure critical tribal knowledge is maintained, for the continuing success of the organization.

Now go forth and prevent.

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