All Features
Mike Micklewright
When considering any effort toward performance improvement, you should always start by looking at the organization’s principles and culture, and making sure these are aligned so they not only permit positive changes to occur, but also ensure that the changes will be sustained over the long run. By…
In the race to design smaller handheld devices and smartphones, a key factor is decreasing the sizes of components. As the demand for thinner and lighter microelectronic devices increases, manufacturers often are limited by how oddly shaped the energy sources must become to make them conform to…
Barbara A. Cleary
When giant companies known for the quality of their products and services find themselves suddenly in the news due to massive recalls—think Volkswagen, Toyota, John Deere, Craftsman, or Chipotle—the first question to emerge often is: What went wrong?
Before jumping to the conclusion that quality…
John Elliott
Fly-fishing, one of my favorite hobbies, is a lot like process improvement. Here’s how: Fly-fishing seems very simple—you throw a line in the water and wait for dinner. Of course, it’s much more complicated than that because rainbow trout are clever; they won’t bite just anything.
You have to…
Thomas R. Cutler
It’s no surprise that multinational companies have complex global supply chains. What’s less obvious is how to simplify supply-chain processes and arrive at a lean, consistent, reliable, and cost-effective solution. One global leader, ITT Corp., has taken on this challenge with the help of Ultriva…
Meredith Griffith
Sponsored Content
Most of us have heard of a backward way of completing a task, or doing something in the conventionally wrong order, described as “putting the cart before the horse.” That’s because a horse pulling a cart is much more efficient than a horse pushing a cart. This saying may be…
Tim Mouw
Detroit recently hosted The North American International Auto Show. It’s an exciting event for consumers who want a sneak peek at what’s on the horizon in the automotive industry: energy efficiency, new gadgets, enhanced comfort, and of course, the latest paint colors and special-effect finishes…
Stephen Mundwiller
One of the more enjoyable discussions I’ve seen on the Internet recently has to be about what to do with the quality manual. A common question is, “So what do I call this thing I put all the procedures in, now that we can’t have a quality manual?” It’s part of the panic brewing among quality…
Davis Balestracci
This article is based on some ideas from my respected colleague Mark Hamel. Despite the lean framework, these ideas apply to any improvement approach—all of which come from the same theory, lean included.
During the past 35 years, quality has evolved from the necessary evil of quality control to…
Jim Benson
When you are a consultant, or worse yet, seen as a thought leader, people hire you expecting that you’ll know “the answers.” At best, what you actually know are paths to make sense of problems, communicate them, and then solve them. No consultant should ever arrive knowing the answers. If they do…
Bruce Hamilton
Here’s a personal reflection from my distant past that might describe a current state for some of you.
When I began working in manufacturing during the pre-lean era, the quoted lead time for my company’s products averaged 12 to 16 weeks. By the 1980s, however, many customers began to routinely…
Manufacturing Extension Partnership MEP
Whether it’s for performance management or for risk, it’s important to know who your suppliers are and have a close business relationship with them.
It’s a given you should already have a strong relationship with your key suppliers, but how often does your supplier request the following items? •…
Paula Oddy
Sponsored Content
As an auditor of quality management systems, I can tell you from firsthand experience that most auditees dislike corrective actions. Corrections are tied to findings of nonconformance; understandably, people generally want to emerge from an audit without any significant findings…
Arun Hariharan
A horrific accident on Dec. 16, 2015, claimed the life of an airline service engineer: He was sucked into the live engine of an aircraft. The engineer had been standing on the ground supervising the aircraft being pushed in reverse from its parking bay.
“No one knew what happened,” said an Air…
Harry Hertz
Even before the landmark publication of In Search of Excellence in 1982, bosses realized that operational excellence gets accomplished through dedicated employees. Yet, to this day, many organizations stifle high performance through the annual performance evaluation process for each employee. This…
Ryan E. Day
Sponsored Content
As global competition stiffens, manufacturing sectors of all stripes are embracing emerging technologies in order to meet customer demands. In the realm of metal casting, Pennsylvania-based Effort Foundry is leading the charge by investing in new technology as part of a…
Dawn Bailey
Dorothy: Now which way do we go? Scarecrow: Pardon me, this way is a very nice way. Dorothy: Who said that? Toto barks at the scarecrow. Dorothy: Don’t be silly, Toto. Scarecrows don’t talk. Scarecrow: [points other way] It’s pleasant down that way, too. Dorothy: That’s funny. Wasn’t he pointing…
Niranjan Deodhar
In the first article of this series, we explored what a process improvement (PI) function would look like if it could apply the principles of reducing waste and variation to its own processes. Here, we build on that analysis to identify the work practices that can drive better, faster, and cheaper…
Mark Whitworth
A recent article in The Wall Street Journal detailing how Boeing is facing up to 24 million dollars in FAA penalties over quality control going back several years across a number of locations shows how even the biggest manufacturers need to close the loop on quality control (QC). Closing the QC…
Fred Schenkelberg
Concurrent engineering is a common approach that pairs developing the product design and its supporting manufacturing processes through the development process. There are several reasons why this is a good idea.
Design engineers may require the creation of new manufacturing processes to achieve…
Davis Balestracci
Marketers are relentless in their efforts to seduce you with fancy tools, acronyms, Japanese terminology—and promises—about their versions of formal improvement structures such as Six Sigma, lean, lean Six Sigma, or the Toyota Production System, each with its own unique toolbox.
In my last column…
Bob Emiliani
Every day, thousands of people confuse lean management with “Taylorism,” properly known as scientific management. The negative association brings out the lean bigwigs and others who work hard to create a great separation between lean and Frederick Winslow Taylor. This is an ill-informed and…
John Bell
How often have you heard people say, “Our strategy is to become the biggest and the best?” This isn’t strategy. Strategy is not the what. Strategy is the how: How will you become the biggest and the best?
Of course, within that definition, there are good strategies and bad ones. Good strategies…
Taran March @ Quality Digest
For those awake enough to respond, please supply the Jeopardy question to this answer: “A computer system that won a million dollars in 2011 with access to 200 million pages of content, including the full text of Wikipedia.”
If you thought, “What is Watson?” you’d be correct as far as the…
Thomas R. Cutler
Quality professionals in most manufacturing plants still have safety under their area of responsibility. Safety has been a growing concern in the workplace for decades, and in warehouse operations, forklift safety is one of the biggest.
OSHA statistics report that more than 100 workers are killed…
