All Features
Jim Benson
If I have been on a decades-long drive to make work more flexible, Alton Brown has been on a similar one in the kitchen. There is no shortage of rants on his various shows about “unitaskers”... things in your kitchen that can only do one thing and therefore are only useful in a few, often unlikely…
Brian Lagas
‘Why are our changeovers taking so long?”
If you’ve asked this question on the shop floor, more than likely you were met with blank stares by your employees. Open-ended questions like this are overwhelming, so employees try to find quick answers that don’t really address the problem. They don’t…
Harish Jose
I must confess up front that the title of this column is misleading. Similar to the Spoon Boy in the movie, The Matrix, I will say, “There is no lean problem or a Six Sigma problem. All these problems are our mental constructs of a perceived phenomenon.”
A problem statement is a model of the…
Quality Transformation With David Schwinn
As some of you already know, I was in Ford Motor Co.’s corporate quality office during the early 1980s when, just after “If Japan Can, Why Can’t We” aired on NBC, we pleaded with W. Edwards Deming to help us out of a very bad place. One of the things I most remember about those times was that he…
Kevin Meyer
My favorite part of a recent podcast with James Clear, author of Atomic Habits (Avery, 2018), was the last five minutes, when he talked about a potential downside of good habits. When we decide to improve and create a new practice with the right cues and rewards, we form a new habit. But habits can…
Jay Arthur—The KnowWare Man
When I first learned quality improvement back in 1989 at Florida Power and Light, the consultants who trained us taught a very specific way to draw a Pareto chart. They’d been trained in Japan, the place where quality improvement first took root during the 1950s, so I took it for granted that the…
Alex Bekker
Do you know what a retailer and a tightrope walker have in common? They both have to balance. For the tightrope walker, the logic is clear. But what’s the balance that a retailer is looking for?
A typical dilemma of shortages vs. storage costs
Although the dilemma of shortages vs. storage costs is…
Mike Micklewright
Industry 4.0 is the current trend of automation and data exchange in manufacturing technologies. Also known as the Fourth Industrial Revolution, it follows behind the previous three revolutions of: 1) mechanization, water, and steam power; 2) mass production, assembly lines, and electricity; and 3…
Jon Terry
Lean solutions represent an evolved method of approaching how business is done. It’s all about transparency, about you and your colleagues being accountable and maximizing efficiency to bring the most value to your customers. At the team level, lean processes help guide teams and individuals to…
Nicola Olivetti
According to a report by PwC, industrial sectors worldwide plan to invest $900 billion in Industry 4.0 each year. Despite these growing technology investments, only a few technologies are significantly mature to drive measurable quality impacts. Digital visual management (DVM) is one of them, being…
Jesse Allred
Lean manufacturing is a philosophy focused on maximizing productivity and eliminating waste while creating a quality product. One of the most powerful strategies in the lean toolbox is total productive maintenance (TPM), a system targeting continuous improvement through a holistic approach to…
Kevin Price
In the world of risk management, maintenance of mission-critical equipment drives priorities and budgets. It is the ultimate test of proactive maintenance and smart decision making. Managing assets that “cannot be allowed to fail” is more than an emotionally charged mandate that forces managers…
Bill Laverty
Operations management plays an important role in the manufacturing process, but similar to a stage crew at a theater, operations managers do all their best work behind the scenes. The best operations managers strive to go unnoticed, and why shouldn’t they? A seamless supply-chain process should…
Boris Shiklo
About 10 years ago, software testing was perceived as the only possible quality assurance (QA) measure for software, according to the World Quality Report 2018–2019. However, QA has since outstepped these boundaries. The QA process now implies that all stakeholders have a direct interest in…
Ryan E. Day
Most of us have heard of kaizen—continuous improvement of philosophy and methodology. In business, this involves all employees working to improve a company's processes to lean it out, to run with less waste. But most of us who are familiar with kaizen think of it as something you do.
Especially, we…
Harish Jose
Today I’m looking at Factory Physics and the Toyota Production System (TPS). My main references for the post are the 1977 paper co-authored by ex-Toyota president Fujio Cho and key ideas from Factory Physics (Waveland Press, 2011).
One of my favorite definitions of lean comes from Wallace J. Hopp…
Mike Micklewright
Knowledge of kaizen theory, principles, tools, and experience in application are of course very important in leading successful kaizen events that drive real bottom-line results. However, equally important are the facilitation skills of the person who is leading the event and the team.
Leading a…
Morgan Sliff
Boeing has been rife with issues lately. While the recent Ethiopian Airlines crash has dominated headlines and elicited an FBI investigation into the company, another federal body has stated it will be keeping a closer eye on Boeing’s safety shortfalls.
Boeing is now in hot water with the U.S. Air…
Ryan E. Day
If you have worked in the quality field for anytime at all, you have probably heard of the Malcolm Baldrige National Quality Award—it’s the highest level of national recognition for performance excellence that a U.S. organization can receive. The award focuses on performance in five key areas and…
Stephen Rice, Scott Winter
In the wake of the Lion Air and Ethiopian Airlines crashes of Boeing 737 Max planes, people are thinking about how much of their air travel is handled by software and automated systems—as opposed to the friendly pilots sitting in the cockpit.
Older commercial airliners, such as the Beechcraft 1900…
Doug Devereaux
Artificial intelligence (AI) is widely acknowledged as a crucial aspect of what is broadly referred to as Industry 4.0. Although no one knows yet how AI will be incorporated into the next phase of the Industrial Revolution, most agree that it will allow greater connectivity between people, machines…
Gwendolyn Galsworth
For me, the operational essence of the leader dilemma is this: How do I say “yes” to the few and “wait” to the many? How do I decide?
The so-called “natural-born leader” is a mysterious (to some, controversial) concept: an individual for whom achievement, direction, and drive seem to come…
Tom Taormina
Outsourcing is historically one of the most misunderstood concepts in quality management system (QMS) implementation and operation. Prior to ISO 9001:2015, the requirement for outsourced processes was limited to a few sentences in the standard’s clause 4.1. This article will present, through a case…
Bruce Hamilton
Last February I had the opportunity to observe healthcare providers up close and personal at one the world’s premier hospitals. “Who Cares for the Caregivers?” was written from the perspective of a patient in a cardiac step-down unit, sympathetically watching caregivers as they grappled with many…
Shobhendu Prabhakar
Historically, conventional wisdom among business managers was that the higher the quality, the higher the cost. This perception still holds true today among a few business managers. Common sense also tells us the same thing, i.e., to create higher quality products or services, organizations will…
