Circle

When we implemented the standardized work, we were told, "The movement forms the circle.”

This 'circle' or En (Yen) is not just a philosophical topic from Zen but a concept deeply rooted in Japanese culture. It holds significant importance in our work, underscoring our crucial role in the process and connecting us to a broader cultural context.

When implementing the standardized work, we will say that the operator’s motion should form a circle. The standardized work starts, and as the worker performs the tasks, the motion should look like a circle from the top view. Ideally, the end and starting points are next to each other, ensuring a seamless flow of tasks, and the worker can move on to the next cycle seamlessly. This movement is drawn on the standardized work chart, where the numbers of work elements are placed and connected. In the end, the connection should form a circle, symbolizing the efficiency and effectiveness of our process.

In Japanese, “circle” is “En” or “Yen.” When I say “Yen,” most foreigners will imagine the currency. The currency's name comes from China, where silver coins are used. China kept the old symbol 圓 and a simplified version of that 元 as its currency. Korea kept the sound and used it as its currency. Japan used the simplified version 円 as its currency. All these currencies have the exact origin.

Yen means a circle. It is used as currency, but this is the original meaning.

This shape captured the attention of the Zen monks. The Rinzai group has drawn many Zen paintings. One of the most popular and essential topics of such drawings is the Enso【円相】. This drawing is just a simple circle, yet it is heavily respected. The teaching or lessons of this drawing are not clearly defined. Some say this represents the ultimate understanding of Buddhism or the truth. Some say this means the universe. Some say the shape of the circle has no start or end point, which means it can flow continuously, representing the heart without greed.

Some call this the “window of heart,” which reflects the author's heart. As a kid, I was challenged to draw a circle with a calligraphy brush—the awkward shape of what I drew demonstrates the status of my heart. Distracted, bored, and lacking interest in calligraphy create an ugly shape.

When we were implementing the standardized work, I mentioned that it is essential to make a circle. An engineer used a compass (drawing tool) to draw a perfect circle on the standardized work chart and tried to walk away. To me, that circle represented the engineer's heart condition.

First, the engineer can’t recognize the motion in detail. In standardized work, there are many motions, including those of hands, feet, and eyes. Focusing on which will change the shape. And most likely, it will never form a circle. But that doesn’t mean we should give it up. Highlight those motions outside a circle and try to keep in a circle. Recognize the waste or the excess motion. Trying to capture the actual state of motion is vital to understanding.

Second, some don’t care to “lie.” Many places have bad standards, fake numbers, and inaccurate procedures—different from reality. Yet, nobody cares. In such a workspace, implementing the standardized work means additional paperwork that will be filled out. They want a checkmark. The gap between the paper and the reality doesn’t matter since the most important thing is the presence of a paper, not the reality. Standardized work is not just paperwork. It must be connected with reality.

Finally but not least, the author doesn’t care about the worker. One reason to draw standardized work is to understand it to make it easier. Every zig-zag motion causes difficulties for the worker. Excess motion wastes time and energy. If drawing is complex, the work must be challenging to perform many times daily. Difficulties should be the subject of Kaizen. If this were inside a house and we had difficult spots to reach, we would change and make our lives easier. Such simple care towards the worker is missing in many places.

Of course, we can’t apply every aspect of Zen to standardized work. For example, unlike some of Zen's claims, standardized work has a clear starting and ending point. Information on what needs to be produced at the starting point is vital. Confirming quality and progress towards takt time at the endpoint is also essential.

But things start to connect when we think of the truth Zen seeks as value-added work, which TPS seeks. Every other thought, which Zen calls Zatsunen, is called Muri (Illogical), Mura (fluctuation), and Muda. My coach used to say, “Synchronize motion and heart.” The ideal condition is for workers' motion and minds to form a smooth circle focusing on the value-added work. Standardized work is a tool to get to such a perfect state.

So, pick up the standardized work and observe the Genba. Is it forming a good circle?