However, as early as 1933, Toyota Automatic Loom Works, which manufactured silk weaving looms, had been requested by the Japanese Government to begin the production of the Type A internal combustion engine to aide in the war effort in China. After the war, automobile production was rapidly resumed.
During this period the company had adapted the philosophy set forth by the U.S. War Department’s Training Within Industry (TWI) Program of Kaizen or “change for the better”.
Loosely translated, Kaizen describes the practice of continuous change or improvement of any given process.
That's right. We taught the Japanese auto industry how to kick our own butts.
In 1947 W. Edwards Deming was brought to Japan by the Supreme Command of the Allied Powers through TWI to advise the U.S. Army and the Union of Japanese Scientists and Engineers on statistical quality control methods and the Shewart Cycle in heavy manufacturing. Dr. Deming’s Shewart Cycle formed the basis for Kaizen,, (which sounds a lot cooler in Japanese than Shewart) from 1947 until 1960. Dr. Deming’s work with the Kaizen philosophy formed the basis of the Toyota Production System (TPS).
So the next time somebody brags about how much better their Lexus is than your Navigator, you can tell them where that "better" came from. But wait...it gets even crazier.
The TPS process is credited with having its inspiration from a visit by Toyota founder Sakichi Toyoda, his son Kiichiro Toyoda and their chief engineer Taiichi Ohno to a Piggly-Wiggly Supermarket while, touring the Ford plant in Detroit.
Upon seeing how a drink dispenser automatically gravity-fed a fresh drink to the next customer, Mr. Toyoda and his associates realized that this process of refilling from consumer demand could be easily adapted to their manufacturing plant and drastically cut the need for vast inventory stock.
From these humble beginnings and the powerful influence of the Kaizen revolution on Japanese industrial practices, TPS evolved into the more expansive Lean Manufacturing Movement.
Simply stated, the Lean manufacturing process is the practice of using less of everything (as opposed to mass production). Lean endeavors to use less human effort, less manufacturing space, less investment in tools and less engineering time to develop the new products that start the process all over again.
Lean also stresses the smooth flow of production, striving to get the right things to the right place at the right time in the right quantity to achieve perfect workflow while eliminating waste and maximizing flexibility.
Lean has become the buzzword of modern industrialization due to the phenomenal success of Toyota as the second largest automotive manufacturer and by far, the most profitable.
Unfortunately many attempts to adapt the “Toyota Way” by other manufacturers have fallen short of their goals. Many have tried to claim this is because of the cultural differences between Japanese and American workers. (as opposed to a trip to Piggly-Wiggly.)
However, the Georgetown Kentucky Toyota plant that is responsible for 60% of the company’s U.S. production is a benchmark facility for Lean manufacturing practices.
Of course, a bigger question is whether or not this philosophy can be migrated from a production-based product environment to a creative-based service environment.
Perhaps in the days of post-war Japan and Dr. Deming’s Kaizen Revolution, this was unthinkable. But much has changed in advertising in just the past few years. Many of these profound changes that effect the current agency have shown that the agency business model has failed to keep pace with the global industries it must serve.
This fact alone makes the agency business model fair game for change. Bored yet? Good. There's more. You agency guys can go dust off your resumes. Client folk, read on.
If we overlay the principals of Kaizen over the latest developments in modern day advertising practices, we can get an idea of how Lean Advertising might just change the game.
Kaizen starts with the standardization of a given task or process.
Although outwardly advertising has a “creative” face, the basic principals have not changed in more than 100 years. Therefore it seems reasonable that these practices can and do lend themselves to standardization.
For the purpose of this document let us look at the standard on-line banner ad. The dimensions are standardized. The pixel weight is standardized. The color spectrum is standardized. The number of words in the copy is finite. The size and complexity of the visual are limited by their download time. The audience is definable. The response is measurable. The cost is known, The return on investment is quantifiable. The effect of the message/offer or action to be taken is able to be determined during specific dayparts. The response can be measured by quantity and (through IP data) location. Most importantly, the result of the ad based upon whether or not the inquiry resulted in a conversion to sales is quantifiable. Therefore, given this data, we can determine our starting point and meet the first criteria of Kaizen.
Once the benchmark is set, Kaizen then moves quickly to measuring the standardized operation in terms of cycle-time and amount of in-process inventory.
Now that we have established the standards set by our banner ad as they relate to size, weight, color, visual and verbal content, intended audience, response perimeters, cost, ROI factors, dayparts, response benchmarks and location data, we can track its performance against time and weight of media buy.
Next Kaizen strives to gauge measurements against requirements.
Now this is where Kaizen or Lean Advertising will differ with today’s standard practice in advertising. Current wisdom in on-line advertising sets sales, click-through or conversion goals for advertising to measure up to.
Lean Advertising, to be true to the principals of Kaizen, is not about pre-set goals. Lean Advertising is about making the advertising better. Change for the better is the stated goal, not meeting an arbitrary sales quota or click-through benchmark or conversion rate. This is a big deal. There is no “finish line” with Lean or Kaizen. Continuous improvement is exactly what it says: continuous.
This means that the current practice of short-term performance metrics gets tossed in favor of long-term effectiveness. This also means that the Lean Advertising process now has the task of taking the entire value chain into consideration when seeking to improve that banner ad.
Improving the product is when Kaizen shifts into high gear.
Everything is up for grabs. At this point Kaizen, and therefore Lean Advertising, will call for innovation to meet requirements and improve productivity. This is where the interests of the Lean organization and their advertising agency come into direct conflict.
Generally speaking, Lean purists are down on outsourcing. Although costs run less, the losses in control and quality assurance neutralize the benefits.
Control is the big factor at this point. If productivity can be enhanced by using a stock photo and the agency Creative Director has an issue with that, the agency has to be ready to tell their CD to step off. This is just one example of how the current agency/client structure will more than likely NOT be responsive to cutting their own profit margins or business/creative prerogatives to meet the demand for improved productivity dictated by Lean Advertising. Uh, oh!
Then there is innovation. What if the innovation is to go with a web buy that doesn’t afford the agency its standard media commission? Whose interest is to be served first? The agency bottom line or the improvement of the banner buy?We all know the answer to that one, right?
The truth is, in the Lean Advertising scenario the agency/client relationship is more than likely the first casualty. Obviously several pilot Lean Advertising programs need to be initiated before these decisions are made, but that is the Lean Way. Test for the best. Forget the rest.
Finally Kaizen seeks to standardize the newly improved process (or banner ad) and then determine if the innovations and productivity gains are an improvement or a setback. Then the entire process starts all over again ad infinitum.
There you have it. The Lean Advertising Process. On the face of it, this methodology could signal a major change in the way advertising is created, produced, evaluated and improved. Obviously, the financial ramifications are enormous; accountability brought back to the marketing department where it belongs; efficacy given a solid set of accountable criteria to adhere to; and the challenge of innovation and creativity applied where it belongs. To making best practices even better and better. All of these efforts focused upon making the practice of advertising more meaningful to the audience.
Next week we will take a look at how a major advertiser might institute a Lean Advertising Initiative and how this new breed of in-house agency might be different from the current system that is currently wasting billions in shareholder value.
Or again, in the words of Morphius, "Welcome to the real. This is a war. We are soldiers. Death can come for us at any time, in any place. There is only one way to save our city."
Stay strong.
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