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| A Japanese Soap Box Assembly Line Story |
When we are confronted with a problem in our lives, most often than not, our mind jumps to elaborate solutions. Such problems can occur all the time and anywhere whether at home or at work. When handling them, we are frequently blinded by our mindset to look for convoluted or complicated solutions. Reason - may be, we think that the problem is complex; therefore perhaps the solution has got to be complicated. We do not even realise this tendency in our personality to look for intricate or involved solutions. This mindset could be a result of the complex modern world we live in or we have to make a six sigma study of everything.
Very often, we even create problems, so that we can show a solution - this is particularly true in several corporates wherein for the purpose of certification or accreditation or promotion, one needs to do a case study, identify a problem, analyse it, devise a solution, implement it and show a resolution that adds value somehow to the bottom-line of the company. Strange as it may sound, many decide to create the problem for which there may already be a solution and then fix it.
Anyway, our point is that often, for problems in our life, we jump to complex solutions rather than commonplace solutions. Such complex solutions are also hazardous in the sense they take a lot of manpower, time, effort and expense. However, the solutions may actually be staring at us and our conditioned mindset typically ignores them for more sophisticated and trendy solutions. To be fair, it is also highly likely that for a majority of us, the obvious solutions are not easily visible. Very rarely are the simplest solutions the most obvious. This is the conundrum that we all experience in our lives. As the popular adage goes, "common sense is not so common".
Here is a popular and famous story illustrating the play of a complex solution versus a simple answer to solve a problem on the assembly line. It is a memorable case study too on Japanese management involving a soap box factory. This particular scenario unfolded in one of Japan's largest cosmetics companies at that point of time. In hindsight, the solution when finally determined appeared to be quite straight-forward and obvious but when the complaints trickled in from customers, it was not so.
It all started when a customer filed a complaint that he had received an empty soap box. The management at various levels including the floor level were alerted and swung into action. The problem was finally isolated to the assembly line. This is where all the packaged soap boxes were transported to the delivery section. For some puzzling reason, one box of soap had gone through the assembly line empty. Engineers were asked by management to study the problem in-depth and find a solution. Immediately, the engineers got to work. A customised X-Ray machine was installed with high resolution monitors manned by people to scan all the soap boxes passing through the assembly line. Any soap box that was empty was promptly identified and discarded. A lot of manpower, time, effort and money was spent on devising the solution. The entire process of figuring out an effective solution was quite expensive and costly. However, the solution worked.
Interestingly, a small company can not afford such a costly solution. So when a similar situation arose in a smaller company, it was presented to the rank-and-file staff to identify a solution that was effective but not expensive. One of the workmen came out with an alternative workable solution. He did not get into complications of X-ray machine, high resolution monitors, oversight staff, scanning, etcetera. He simply went out and bought a strong industrial model of an electric fan and pointed it at the assembly line. He switched the fan on, and as each soap box passed the fan, it simply blew the empty boxes out of the line.
As noted, in hindsight, the solution was obvious but the mind also needs to be trained by us to think of simple solutions that are effective in every manner possible. This may not happen overnight but with the right kind of patience and perseverance, it is possible to do so. Experience also does help. It is therefore equally important to involve all relevant parties in figuring out the solution. The wisdom of the crowd and brain storming at all levels can be of great help.
➤ Life Lessons: Always look for simple solutions that solve the problem in an effective manner involving minimal time, effort and expense. Avoid complications. Focus on solutions and not problems.
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