Moonshining Kaizen: solving problems with creativity, not your wallet

Table of Content:

Introduction

Moonshine Kaizen

Why Experiment

Case Study 1: Improving Public Space Cleanliness

Conclusion

Case Study 2: Improving Patient Care Efficiency

Bonus

Introduction

Moonshining is a term that often brings up images of the infamous illegal alcohol production in the United States. However, many people are unfamiliar with its broader implications.

While many in the U.S. are familiar with the traditional definition of moonshine, those outside the country might need some clarification. During Prohibition in the United States, individuals illegally produced liquor, often at night, using the moon as a light source (perhaps fiction) and the dark to hide smoke. (Source: Wikipedia) The materials and equipment they used varied widely, with moonshiners creatively repurposing available resources. No two setups were identical.

In the context of Lean/TPS, moonshining is typically part of a 3P kaizen (Production, Preparation, Process) and has of course nothing to do with alcohol production. Instead, it embodies the 'make do' mindset. This concept was championed by Mr. Chihiro Nakao, co-founder of Shingijutsu Consulting Company. In his book Kaizen Forever, Bob Emiliani highlights how Mr. Nakao emphasised creating new solutions within existing conditions rather than purchasing ready-made solutions which may or may not work. If you haven't yet, I highly recommend reading Kaizen Forever and Shingijutsu-Kaizen by Bob Emiliani. These books offer a profound understanding of Kaizen, especially if you haven't had the opportunity to work with Shingijutsu senseis from Japan. These books very well capture the essence of Kaizen & Shingijutsu-Kaizen, aligning with my experiences. We referred to these events as 'Shingi' and to me these were the “crown jewels” of our Kaizen initiatives.

Moonshine Kaizen

With this background in mind, let's return to the concept of moonshining. It focuses on innovation, encouraging the creation of new ideas and solutions within existing environments. This approach emphasises critical thinking and a 'no-nonsense' attitude, bypassing traditional, often tedious methods like forming task forces or over-analysing problems. Moonshining draws inspiration from nature, enabling teams to create prototypes through 'try-storming,' often referred to as 'cardboard engineering.' These initial prototypes, made from materials like cardboard and wood, make the creation process accessible to everyone. It brings to mind the old American TV series MacGyver, where the protagonist could create anything using only scrap parts and duct tape.

In a moonshine kaizen, mockups are created as working prototypes that serve as the foundation for professionally made tools or equipment. These prototypes allow team members to test and provide real-life feedback for improvement. Sometimes, in the true spirit of moonshining, the prototype itself becomes the final version if it fulfils its intended function perfectly. However, it's important to remember the principle of 'kaizen forever,' or continuous improvement, meaning these solutions must evolve and adapt to new circumstances over time.

Why Experiment

Because it ensures that new ways of working are sustainable. If those who will benefit from the change are directly involved and have a say, the change is more likely to be successful. If the change doesn't benefit everyone, it shouldn't happen. Experiment or 'think' with your hands rather than your head. When we manipulate physical objects, our brains are more active and creative. This is because our hands are able to explore and shape the world around us in a way that our minds alone are unable to do. This experimenting is a group exercise, not a one-person job and it must takes place in a real environment rather than on a computer screen. Not everyone can use design software.

A good example of this concept is found in landscaping: we've all seen a worn path in the grass next to a paved walkway. In landscape planning, this is called a 'desire path.' According to Wikipedia, a desire path is an unplanned trail created by human or animal traffic, representing the shortest or most navigable route between two points. The width of the path and the degree of erosion often indicate the volume of traffic. If the area had been left alone for some time for people to use, they would have marked where the path should be, rather than the other way around. If you see one of these, let it be a reminder to always experiment with a group in a real environment.

To those unfamiliar with moonshining, it might seem amusing or even absurd. However, I would like to share some examples from my own experiences to illustrate its broader applications. Many people mistakenly believe moonshining is only for production, but this couldn't be further from the truth.

Case Study 1: Improving Public Space Cleanliness

I aim to recreate what the original problem might have been based on my personal experiences, as I was not directly involved. I observed this scenario in a public park in Switzerland while passing by. Credit goes to those who implemented this solution in the Park. (Photos I took myself)

Problem Statement

Visitors to the park enjoy themselves, often bringing or ordering pizzas and other takeaways that come in boxes. These items are frequently left behind making the park challenging to maintain and fill up the bin making it unusable for other recycling waste. Additionally, a beach restaurant in the park serves takeaways and drinks, likely facing issues with plates and glasses not being returned or discarded properly, leading to them being scattered across the grass.

Moonshining Prototype

Although I was not involved in the creation, I assume that before building the prototype shown in the photo, the team likely brainstormed ideas on paper and decided to test one (or possibly multiple — I only saw one). The prototype was constructed from wood, with clear instructions for users on its purpose and intended use.

Experiment/Testing the Prototype

In any moonshining activity, testing in real life is crucial to determine whether the proposed solution effectively addresses the problem. Gathering user feedback, making adjustments, and iterating are essential steps. Since the prototype is made of wood, it is easy to modify and adapt as needed. They were likely testing whether the space was sufficient for accommodating pizza boxes, both in size and volume, and whether people would collect and return restaurant plates and glasses to this designated area.

Final Solution

I returned about a year later, so I'm unsure how long the testing phase lasted. However, it's reasonable to assume they tested it for one summer season before concluding that it was effective. Additionally, they introduced cigarette butt holders at the same trash collection site, making them available for use.

Results/Outcome

The park was free of pizza boxes, cigarette butts, and other trash, and the restaurant successfully retrieved its items. This outcome demonstrates the effectiveness of the moonshining approach in addressing the park's cleanliness issues.

Case Study 2: Improving Patient Care Efficiency

I recently led this moonshine kaizen in an animal hospital.

Problem Statement

The staff was taking too long to set up monitoring and infusion equipment for stationary animals in the clinic. Infusion bags were sometimes hung in front of other cages, making it difficult or impossible to open the adjacent cage doors without having to reset everything. Due to unsecured machine positioning, these infusion or monitoring machines often fell to the floor and broke, necessitating the purchase of new machines and temporarily complicating work due to equipment shortages. Additionally, patient documentation was meant to be stored with the patient but was often destroyed by the animals or damaged when placed on the cage doors. Previous attempts to address this issue using other methods were unsuccessful due to the high breakage rate of the materials used.

Moonshining Prototype

A team of nurses and doctors gathered to discuss the challenges each faced when working with hospitalised animals. They shared past experiences with similar situations and listed all previous actions taken to mitigate the issues. These concerns were recorded and categorised. Based on each problem group, team members proposed potential solutions and hand-drawn sketches were created. After selecting the favoured solutions, we embarked on a journey constructing a working prototype using wood, cardboard, and duct tape.

Experiment/Testing the Prototype

This prototype was installed in the clinic, and team members were asked to test it by moving the movable parts, hanging items, and providing feedback on their experiences. The feedback was used to modify the prototype, and the testing was repeated. Once the team approved the design, a CAD manufacturing design was created to facilitate production, plus the manufacturer was able to view the prototype, simplifying communication.

Final Solution

The first doors were modified according to the prototype and testing continued with this model. I prefer this additional step and find it especially beneficial for teams undertaking this activity for the first time. It helps building confidence in both the team and the process. Furthermore, it provides an opportunity to make any necessary adjustments without incurring significant costs or having to redo everything if unexpected issues arise despite prior testing.

Results/Outcome

Animal cages are now equipped with this new system, enabling the team to set up each cage more efficiently. The preparation time for the monitoring and infusion system has been reduced by approximately 70%, and the equipment fall rate has dropped to zero. Additionally, the new system offers a convenient way to store documentation on the cage doors while preventing animals from damaging the holding tools and papers. (Cats are crafty animals, and they somehow always find ways to scratch and chew things, so time will tell if this system withstands their antics. 😊)

The benefits of the modified door design include:

• Reduced setup time for infusion bags and equipment

• Improved patient monitoring and safety

• Better organisation and accessibility of patient belongings and documentation

The concept of moonshining, originally linked to illegal alcohol production, has transformed into a valuable metaphor for innovation and problem-solving. By adopting a "make do" mindset, teams can effectively tackle challenges through collaboration and iterative testing.

The examples above highlight the importance of teamwork, creativity, and continuous improvement in fostering practical solutions that enhance efficiency and user satisfaction. Embracing the principles of moonshine kaizen can lead to meaningful change across various industry sectors.

Conclusion

Bonus

How Can I do a Moonshine Kaizen?

Safety:

This may seem obvious, but just to be sure. No matter what you are trying to do, it is best practice to keep the team involved safe during the activity, and they need to be aware that the solution they are developing has to meet all company and government requirements for safety standards. They will also be working with their hands, which may be a greater risk for some coming from an office environment. Always have a safety reminder / education section at the beginning of your moonshining kaizen to raise awareness of potential hazards and risks to prevent accidents.

The way from the problem to the solution through the Staircase of Moonshining:

Team:

• have at least one person from the actual area you are focusing on

• members should be from cross-functional groups (including managerial functions)

• keep the team small 6-8 people (max 10, but really not more than that)

• ensure team members understand humility – there are no bad ideas!

• attentive participation – no laptops, no emails, no “oh, I have a meeting to go to”

The Spirit (no pun intended):

• get out of your head – start doing instead of only thinking of a solution, make and test multiple possible solutions and evaluate them by actual trials (try-storming)

• there are no single heroes – it is a group activity, more people will solve a problem easier then one alone

• money does not solve all your problems – use your head rather then your wallet (exclude expensive ideas)

Material (just a quick list from the top of my head… add anything you can find laying around and seems useful to you):

pen, paper, paper towel, post-it, rope, cloth hanger, light bulb, wire, rope, wheel inner tube, ply-wood, biscuit joiner, hardboard, cardboard (sheet or box), duct-tape, fishing string, spray, bolts, nuts, screws, etc...

Machines:

If you take this seriously, and you really should to get the full benefit of moonshining kaizens, you will need to develop your own 'moonshine shop', filled with the machinery normally required for DIY projects, and perhaps a bit more if you have a need for some specialist tools.

Alternatively, you can contact a consultancy such as myself and through our partnership I can not only help you prepare and lead/facilitate a moonshine kaizen, but I may also be able to help you organise the production of the items you need.

Moonshine:

1. GTG – (Go to Gemba) – Everybody on the team has to see and understand what is the focus area and process

2. Generate multiple concepts (seven is usually a good number) to ensure you really have stretched the teams imagination. If the team only has one-four ideas, you are doing it wrong! It is getting interesting after 5 only

3. Rank the concepts in order of team preference then Moonshine the Top 3 concepts

4. Test then select your top candidate

5. Moonshine again the top idea - Use the feedback from each test. It's often the case that certain functions, forms or features perform well, but the overall concept in which they are included does not. These useful elements could then be creatively combined to form a new concept, or simply incorporated into some of the better performing concepts to make them even better. In this way you can improve the effectiveness of your concepts and maximise their potential

6. Refine this top concept

7. Make the solution into the operation (safety first!!!, and of course ensure it meets all standard requirements of the area it is going to be used)

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