All Features
Ken Levine
How do you determine the “worst case” scenario for a process? Is it by assuming the worst case for each process task or step? No. The reason is that the probability of every step having its worst case at the same time is practically zero. What we’re looking for is a value that will occur a very…
Fred Schenkelberg
A fault tree analysis (FTA) is a logical, graphical diagram that starts with an unwanted, undesirable, or anomalous state of a system. The diagram then lays out the many possible faults, and combinations of faults, within the subsystems, components, assemblies, software, and parts comprising the…
Michelle LaBrosse
Ihave studied systems dynamics modeling for three decades. What I’ve experienced first-hand is that when you establish several key core values, you can create an entire self-replicating system for your organization.
I experimented with this idea first with Cheetah Learning, where our three core…
More than 313 million global work-related accidents occur each year, according to the International Labour Organization, with a high percentage of those accidents resulting in significant time away from work. Each accident bears a personal and financial cost for the worker and the employer. Yet,…
Debby Newslow
Standard operating procedures, or SOPs, are critical to quality assurance. Frequently, in an operation with many associates, each one does his or her job as well as possible (because no one wants to do a bad job). Some people, however, will do tasks differently than others—and usually they think…
Ryan E. Day
Sponsored Content
In the most basic terms of engine exhaust theory, more flow equates to more performance. The aim is to improve the efficiency of your vehicle’s engine, boost performance, and save money on fuel. Auto-jet Muffler Corp. has implemented that “improved flow = improved performance”…
Davis Balestracci
In my last column I explained how many situations have an inherent response surface, which is the “truth.” However, any experimental result represents this true response, which is unfortunately obscured by the process’s common-cause variation. Regardless of whether you are at a low state of…
Jason Furness
Here’s a “tales from the real world” extract from our book, Manufacturing Money (Amazon Digital, 2015). It offers an example of the “five focusing steps” to improvement, with a particular focus on step one, identify the constraint; and step two, maximize the constraints output.
This was a time…
Annelise Orleck
Pico Rivera is a dusty working-class Latino suburb of Los Angeles. After the school district, Walmart is the city’s largest employer and the source of 10 percent of its tax revenue. More than 500 families in the town depend on income from the store. The town is also the epicenter of activism by…
Harish Jose
In this article I want to look at the concept of equifinality in relation to the plan-do-check-act (PDCA) cycle. In systems theory, equifinality is defined as reaching the same end, no matter what the starting point was. This is applicable only in an open system, one that interacts with its…
Thomas More Smith
Last month, the U.S. Department of Labor outlined changes to the existing overtime exemptions. Is this a win for workers? And a loss for employers? In truth, the real effect on both groups and the economy is much more nuanced.
As you are probably aware, some employees are exempt from being paid…
Barbara A. Cleary, Steve Daum
Quality alone will not ensure a successful future, as the classic story of the buggy-whip manufacturer demonstrates. His products were outstanding—better than any others—but when the market changed to automobiles, he found himself out of business.
Markets do indeed change, apparently at an…
For true freedom of design, 3D metal printing enables incredible solutions in industries as diverse as manufacturing and medicine. Now the technique has generated a humane resolution to a difficult problem confronting a team of veterinarians. For the first time ever, a prosthetic titanium beak has…
Ben Vickery
A manufacturer can be innovative in various ways by using new business models and adopting measures to improve processes and enhance existing products. But to stay ahead of competition, manufacturers often turn to technology. Here are five technologies that are driving manufacturing innovation.…
Fred Schenkelberg
When products were crafted one at a time, the design and manufacturing processes were often done by the same person. For example, a craftsman would design and build a chest of drawers or a carriage. Some trades would employ apprentices to learn the craft, which also included design.
Larger…
Donald J. Wheeler
The simple process behavior chart can be used in many different ways. Since report card data are common in all types of businesses, the report card chart is often the first chart that people create. Some of the pros and cons of report card charts are covered here.
Report card data are data that…
Chad Kymal
The aerospace standard AS9100 Revision D was originally planned to be released in April 2014. Many of us close to the standard expected it to be released in May 2016 after the April International Aerospace Quality Group (IAQG) meeting in Singapore. However, this was not the case; the IAQG decided…
Mike Beels
It’s amazing that, in this day and age, some manufacturers have not yet heard of “lean.” How are they surviving in today’s competitive market without it? The issue is that, in many ways, the customer sets pricing. If manufacturers want to be profitable, they must find ways to become more efficient…
John Bell
Should every company be striving for the type of strategic advantage that has become the hallmark of Amazon, Google, and Facebook? For sure, in the tech world, it’s hard to imagine success without quick and continuous technology improvement. What about your world?
Whether you sell information or…
Stephan Manning, Marcus M. Larsen
One of the big themes in the current presidential race is how decades of free trade have dealt a heavy blow to the U.S. worker as millions of jobs were shipped overseas to take advantage of cheap labor.
That’s even turned some pro free-trade Republicans into protectionists. As a result, the…
Harish Jose
May 8 was Mother's Day. In today's article I will be writing about somebody who has been called "The Mother of Modern Management" and "America's First Lady of Engineering." Many of this woman's concepts and ideas lend themselves really well to the Toyota Production System.
Lillian Moller Gilbreth…
Patrick Runkel
The Pareto chart is a graphic representation of the 80/20 rule, also known as the Pareto principle. If you’re a quality improvement specialist, you know that the chart is named after the early 20th-century economist Vilfredo Pareto, who discovered that roughly 20 percent of the population in Italy…
Evan Miller
Sponsored Content
PLZ Aeroscience is North America’s largest custom aerosol manufacturer and packager. It produces its own private-brand products and custom formulations, and provides contract filling for other customers. PLZ has been in business for more than 100 years and during the last six…
Takehiko Harada
Editor’s note: This is an excerpt from the book, Management Lessons From Taiichi Ohno: What Every Leader Can Learn From the Man who Invented the Toyota Production System, by Takehiko Harada (McGraw-Hill Education, 2015).
The phrase, “kaizen equals getting closer to the final process” was hardly…
Gwendolyn Galsworth
Visual scheduling is a plain, two-dimensional format that maps out which products, parts, or subassemblies need to be produced, and when, in what quantity, and in what order. Nothing could be simpler.
In companies where schedules aren't published in a single, centralized location for all to see…