Volume 1 / Issue 9 / July 18, 2016
Gulls were not the Targeted Customer...The Results?
SPECTACULAR. Other than to confirm a 50% waste reduction, we will not provide the numbers because they are proprietary but here are some of the realities. In the clam business it is reasonable to say that a high percentage of the meat that is harvested is lost during the process – a number that is not that unusual when you look at the total enterprise and all wastes therein. Keep in mind that some 55% of all books printed in North America are shredded which means the useless destruction of one heck of a lot of trees. As it turns out, the entire project had the company looking for a 50% reduction in wasted clam meat and, consequently, a huge increase in the product brought back to the dock.
The biggest change was the change in the Gemba Thinking among the process owners! No longer was each hand just coming on board ‘to go to sea’ now they were ‘going to sea’ to bring the most meat possible back to their customers on land. The change was simple and profound.
Is everyone on the same page in the process?
No, but they’d like to be, because it is awfully difficult to be proud of what you do when there is mass confusion
Does everyone think the same about what they’re to do?
Heck NO! So let’s test it and see--- this was an eye-opener
“Why does the boat go to sea?”
To harvest clams. NO, that’s wrong thinking as it does not focus on the highest value activities.
The boat goes to sea to bring back the largest quantity of product possible not just to harvest clams. When you focus on fishing, or sales, or clamming, with all your might and bonus your folks accordingly, it is the same as providing incentives for your people to keep machines running even when there is no customer for the product. And the result is that the accumulated materials are often sold at fire sales if they are sold at all. However, if the focus was on bringing back the maximum amount of product, they would look at the entire flow differently and think about where the bottlenecks and waste were occurring.
For years, the focus had been on harvesting clams but a careful inspection revealed that what was really going on was that the internal processes in the floating factory (the boat) just could not handle the peaks which caused clam meat to overflow and become completely lost, expelled by the bilge pumps to the delight of the gulls who were not the targeted customers.
By slowing the rate of harvesting (a shocking mindset change) far less was wasted but “that was a tremendously hard habit for us to break,” commented a Senior Clearwater Seafoods leader. Nonetheless, at the end of the trip, a lot more product was available for sale in the same amount of time and at no more expense for fuel.
The VSM exercise opened eyes. It enabled people, who had fished all their lives, to actually see the flow of the value stream for the first time and once it was visible they needed little further help. For this reason, the U.S. is training increasing numbers of people to Value Stream Map their manufacturing operations through their Manufacturing Extension Partnership centres. And they are doing it to make the value streams clear so that common sense can take over. Our congratulations go out to Clearwater for having the vision, the courage and the follow-though to deliver increased capabilities to their people and to their company that will enhance their already world-leading competence. Their fresh thinking is one reason why they are currently the world leaders when it comes to clam fishing.
Bob’s reflection? "This was my first non-traditional Lean implementation and it opened my eyes to the power of Lean, no matter what your business is." Bob is happy as he finds that the land he now walks upon no longer rolls beneath his feet.
AN ATJ ADDED BONUS! Enjoy!
LINGUINE WITH CLAM SAUCE
BY STANLEY TUCCI WITH JOAN AND STAN TUCCI, AND GIANNI SCAPPIN AND MIMI SHANLEY TAFT THE TUCCI COOKBOOK
4/4 fork user rating
According to my father, this was one of Nònno Tucci's favorite sauces to make. "He preferred to open the clams himself," recalls Stan. "He would collect the juice and remove the clam meat, making certain to collect all the juice. In the summer when we had large outdoor parties, we often served a bushel of raw clams on ice. Any remaining clams were prepared following my father's methods and frozen. They defrost quickly, providing a meal in the time it takes to cook the pasta."
If your fish market will open the clams and reserve the juice, it will save a lot of preparation time. If not, wash the clamshells thoroughly. Open the clams over a large bowl to catch the juices. Remove clams, discarding the dark sac, and set aside. Strain the juice through a fine-mesh sieve to remove sand and shells. Add the clams to the strained juice. Begin to prepare the sauce when the pasta is halfway cooked.
1 pound linguine
1/2 cup plus 1 tablespoon olive oil
6 cloves garlic, finely chopped
1/4 cup dry white wine
18 littleneck or chowder clams
Kosher salt and freshly ground black pepper
1 tablespoon chopped fresh Italian, flat leafed parsley
Bring a large pot of salted water to a boil and cook the pasta, following the package instructions, until al dente.
Meanwhile, warm 1/2 cup of the olive oil in a high-sided saucepan set over medium-high heat.
Add the garlic and cook until softened, about 2 minutes.
Add the wine and allow it to cook away slightly, about 1 minute.
Add the clams and their juice, and season with salt and pepper.
Cook until the broth froths to a level of 1 to 2 inches.
Remove from the heat.
Stir in the parsley.
Drain the pasta and toss in a serving bowl with the remaining 1 tablespoon olive oil.
Distribute evenly among six dinner plates.
Top with equal portions of the sauce, and serve immediately.
Light white and full white VARIATIONS: The same dish may be prepared without removing the clams from their shells, making for a less formal, hands-on meal. Warm the olive oil in a pot large enough to hold the clams in a single layer. Add the garlic and cook until softened but not browned, about 2 minutes. Add the wine and allow to simmer and sweeten, about 2 minutes. Add the clams and parsley, and cover the pot. Cook until the clams open, about 5 minutes. Season with salt and pepper. Remove from the heat and spoon over cooked pasta. Be sure to discard any unopened clams.
Reprinted with permission from The Tucci Cookbook by Stanley Tucci with Joan and Stan Tucci,
and Gianni Scappin and Mimi Shanley Taft, © 2012 Gallery Books