All Features
Albert Rees, Joe Vernon
The pandemic had many consequences for manufacturing companies, the most prevalent being supply chain disruption. In light of these disruptions, it is paramount that organizations establish robust and reliable operations to ensure productivity targets are met—especially as consumer demands continue…
James J. Kline
Big data is a relatively new phenomenon. Its use is increasing in many organizations. But, as with many new processes, its use cuts both ways. It has positive benefits to both the organization and customers. It also has its potential downside. This piece looks at both with respect to the quality…
Brandon Cornuke
Manufacturers work hard to minimize disruptions to their operations and invest significant resources to minimize production risk. They also are under constant pressure to find new ways to deliver more value to their customers. Sustainable business growth is critical to delivering this value. Many…
Emily Newton
There’s no better time than now. As a species, we need to mitigate the effect we have on our planet. There are many ways to do this—namely, through green and eco-friendly initiatives—but one sector is having the biggest impact of all: the industrial and manufacturing sector. In the 2010s, the…
Harish Jose
T he dictum, “purpose of a system is what it does” (POSWID) is famous in cybernetics, attributed to the management cybernetician Stafford Beer.
Beer notes: “A good observer will impute the purpose of the system from its actions and thus from the resultant state.”
Hence the key aphorism and acronym…
Bruce Hamilton
In 1985, about the time I was discovering there was a better way to produce products, The Natural, a film about an aging baseball player with extraordinary talent, was garnering multiple Academy Awards. This archetype concerning natural “God-given” abilities is common in Western culture—in sports…
Knowledge at Wharton
Negotiating a salary increase or a job promotion ranks high on the list of hard conversations to have at work, and it doesn’t get any easier without a plan.
“People think, ‘I’m just going to knock on their door, sit down with them, and noodle around and see where this goes.’ That’s not a plan,”…
William A. Levinson
Ryan Day1 describes how the rise of independent auto dealers is a “gray swan” event for the automobile industry. This was not only bound to happen, as observed by the author, but also long overdue. The article states, “...current state laws prohibit OEMs from selling new vehicles directly to…
Anthony Tarantino
In 2007, Nassim Taleb described black swans as highly improbable events that had dramatic or even catastrophic effects on markets and economies. Until recently, it seemed that such events were indeed rare.1 There’s now a major rethinking with the world entering the third year of the Covid-19…
Bruce Hamilton
The level of excitement was high in our machine shop as we drew closer to our goal of less than 9-minute changeovers on the BNC lathe. (See Part One of this story for how we got there.) Setup improvements had so far reduced changeover time to 20 minutes, cutting the economic order quantity from…
Jonathan Gilpin
The world of procurement is often tricky. It involves choosing one appropriate candidate, ultimately benefiting them while rejecting and disadvantaging others.
That said, it isn’t just the businesses picked that will profit from winning the contracts; it’s also their supply chain, their local…
Bruce Hamilton
We had been working with the Toyota Production System Support Center (TSSC) for two years to build a model line in our assembly department. As we moved from small batch production to one-by-one, the results had been astounding: Customer lead time reduced from two weeks to one day, crew size cut in…
V R Vijay Anand
As the world moves toward a new, post-pandemic normal, industries must leverage digital transformation at an accelerated pace. This is already happening. According to IBM, 67 percent of manufacturers have accelerated digital projects since Covid-19.
Although improved operational efficiency is…
Bruce Hamilton
Every February, there are welcome reminders that spring is on the way. The first for me is a witch hazel bush in my front yard that defies subfreezing weather to produce fragrant yellow flowers. Then, a few weeks later, crocuses and winter aconites will emerge from the snow. The cycle continues…
Keith Groves
The lean manufacturing movement evolved from a desire to reduce waste and inefficiencies and improve productivity on the shop floor. Many manufacturers have also benefited from the resulting continuous improvement mindset as engaged employees became empowered to change things for the better.…
Anthony Murphy
Kendrick Plastics is an IATF/TS 16949-certified, tier one and tier two supplier of interior decorative trim components and assemblies to the automotive industry. Located in Grand Rapids, Michigan, its 300,000 sq ft engineering and manufacturing facility has more than 50 presses serving fully…
Jamie Flinchbaugh
Editor’s note: This is an excerpt from the new book People Solve Problems: The Power of Every Person, Every Day, Every Problem (Old Dutch Group, 2021) by Jamie Flinchbaugh.
For anyone reading this who is familiar with my teaching, this will come as no surprise: Problem-solving tools are not the key…
Gleb Tsipursky
‘I don’t see how we can replace the serendipitous idea generation of hallway conversations,” said Saul, the director of quality management for a 1,500-employee enterprise software company, during a planning meeting about the company’s post-vaccine return to the office. “If we don’t return to the…
Theodoros Evgeniou, Caroline Zimmerman
This isn’t a new story: A novel technology disrupts society, bringing with it many benefits but also major risks and costs. We saw it during the Industrial Revolution, which vastly improved the average living standard but also led to poor labor conditions and environmental degradation, all within a…
Emily Newton
Welding technology has progressed over the years, thanks to innovations that improve accuracy and overall productivity. Some advances have been in welding automation handled by advanced robots. Other breakthroughs rely on artificial intelligence (AI) and machine vision for better defect detection.…
Bruce Hamilton
You may recognize the following quote from Friedrich Nietzsche, or more recently from Kelly Clarkson: “What doesn’t kill you makes you stronger.” I’ve thought about this often during the last 22 months in context of the horrible pandemic and, more parochially, in relation to the efforts of many…
Anthony D. Burns
I’m a chemical engineer. The fundamentals of the chemical engineering profession were laid down 150 years ago by Osborne Reynolds. Although chemical engineering has seen many advances, such as digital process control and evolutionary process optimization, every engineer understands and uses Reynold…
Sybil Derrible, Juyeong Choi, Nazli Yesiller
Communities across the U.S. Southeast and Midwest are assessing damage from the deadly and widespread tornado outbreak on Dec. 10–11, 2021. It’s clear that the cleanups will take months and possibly years.
Dealing with enormous quantities of debris and waste materials is one of the most…
Bruce Hamilton
In 1996, the TSSC (Toyota Production System Support Center) began working with my company to create one-by-one production capability in our product assembly. Previous to TSSC’s assistance, we’d moved the furniture and machines into cells, creating the appearance of flow production, but we lacked…
William A. Levinson
Shigeo Shingo was able to summarize entire concepts in single phrases, such as “paint parts, not air.” This meant that paint which misses parts in a spray booth constitutes wasted material and also an environmental aspect. “Ship product, not air” defines similarly empty space in packaging as wasted…
