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Lean Six Sigma methodologies have been around since Henry Ford’s creation of the assembly line in the early 1900s. Yet, companies that turn to lean Six Sigma often find themselves defending against the stigma that it stifles creativity, turns people into robots, or is just another way to get more…
Greg Hutchins
Toyota is in the news daily for its safety-related recalls. It’s sad… no, tragic. How could a company’s quality reputation be diluted so quickly? The pundits are saying that it will take many years to regain its lost quality reputation.
For Toyota, its reputation was its most important asset—…
The powder metallurgy (PM) process offers manufacturers the ability to produce high volumes of complex parts in a cost effective manner. Many powder metallurgy components go through heat-treat processes producing parts with increased strength or wear resistance. To ensure the quality of the heat…
Raissa Carey
Clothing items from world-renowned fashion brands such as Versace, Hermés, Dolce&Gabbana, Hugo Boss, and Trussardi were recently found substandard during a quality check performed by the government of China’s Zhejiang province, a wealthy part of the country on the eastern coast, near Shanghai…
Jon Miller
I received pair of questions about lean logistics over the past few weeks that prompted this article. The questions were “What is the milk run method?” and “What is the role of the water spider?”
The milk run
The milk run is an example of time-fixed, quantity-variable replenishment of…
Eric Clower
In July of 2008, I stepped out of an engineering leadership role and into an operational role. The transition was exciting and overwhelming. While I had been in and around manufacturing for a little more than a decade, I had never operated as a part of supply chain or production management. The…
The Un-Comfort Zone With Robert Wilson
I was leaving my last class for the day when I saw my friend, Ken Frankel, working out in the hallway with one of those pistol-grip label makers. I stopped and asked what he was doing.
“The dean asked me to put the room numbers up in Braille so the blind students can find their classrooms…
Capture 3D
Today’s challenges in the turbine industry to meet the ever growing requirement to manufacture parts faster, on schedule, and at reduced costs, have made it apparent to industry experts that traditional inspection methods are too slow and inadequate to achieve the required results. With the…
Michelle LaBrosse
When there’s a lot going on, we often push the fundamentals aside and forget the basic skills that have been part of our success. Project management has been a central part of my own success from the beginning of my career. So, when I’m faced with new challenges or when I’m wondering why a project…
Mike Micklewright
Nearly 30 years ago, W. Edwards Deming gave us his 14 Points for Management regarding how Western management must change. His 11th point was actually two points:
11a) Eliminate work standards (quotas) on the factory floor. Substitute leadership.
11b) Eliminate management by objective.…
Akhilesh Gulati
Toyota’s name has been plastered in the headlines providing it the publicity no organization would wish for.
Historically, Toyota had achieved a global reputation for the production of very high quality vehicles. The Toyota Production System, or the Toyota Way, is being taught, learned, and…
Bill Kalmar
One of the elements of a successful community is a strong school system. Real estate brokers will always discuss the educational resources in a community when showing homes to prospective buyers. There should be no argument that schools are the lifeblood of any community.
During the last…
Denise Robitaille
Ok, men. Leave the room.
Today, I want to discuss fulfilling customer requirements as they relate to one particular product: The bra. For those men who’ve not heeded the warning to leave, you may, by the end of this article have discovered, one of the perennial reasons for your spouse’s…
How a country copes with a brutal economy depends in no small part on how well its people maintain their confidence in their own personal financial future. Will consumers be confident enough to spend? Will investors be confident enough to buy? Will employers be confident enough to hire?…
Oriel STAT A MATRIX
After years of focusing on the pharmaceutical industry and establishing better controls for reviewing the safety and efficacy of pharmaceutical products prior to approval, the Food and Drug Administration (FDA) is now directing its attention to the medical device industry.
On Feb. 18, the FDA…
Tim McMahon
A management system is the framework of processes and procedures used to ensure that an organization can fulfill all tasks required to achieve its objectives. A lean management system consists of the discipline, daily practices, and tools that you need to establish and maintain a persistent,…
Steve Moore
The following words of an anonymous poet as he (or she) immortalized the lessons from Deming’s funnel experiment.
“Tamper, tamper is the game, try to make all the same. Squeak and tweak it every day, off we go to the Milky Way.”
—Anonymous
I offer a corollary that may help…
GKS Global Services
A mechanical engineering firm was contracted to install new cooling equipment in a municipal ice rink’s mechanical room. The challenge was to design the equipment installation without tearing out the old equipment first, and to install some elements and piping that housed the refrigerant around…
R. Eric Reidenbach Ph.D.
“Our corporate mission is to deliver the ‘Best Value in Energy and Related Services,’” according to a large Midwestern electric and gas utility company. This is a mission statement, which after a minor modification (just change the industry), could be posted on any boardroom wall and inserted into…
Stewart Anderson
Organizations can be considered as systems of processes whose aim is to achieve customer satisfaction by meeting and filling the needs of customers. The famous flow diagram of W. Edwards Deming, illustrated in figure 1, shows an organization as a system and illustrates how certain key processes…
Georgia Institute of Technology
The cross-functional team at Piedmont Newnan was made up of employees that deal with the process daily. For this process improvement project, they focused on case carts, which are used for pulling together all supplies needed for surgical procedures.
Pam Murphy, a…
Louis Sirico
Aerospace and other manufacturing industries have accelerated outsourcing of manufacturing operations to increase efficiencies and reduce costs. However, moving some of the operations outside of the traditional four walls of the factory has created “dark areas” in the manufacturing visibility…
H. James Harrington
With the onset of Six Sigma methodology, many organizations have spent large sums of money to make all of their products and processes as close to six sigma as they can. I agree that the higher the level of sigma value, the better the quality of the output is if it’s not screened. But is that the…
Robert Parsons
The AS9100C standard (also referred to as AS9100:2009 and AS9100 Rev C) has been published since January 2009. You are not alone if you are confused about the delay in being audited to this standard. Like you, most companies seeking registration to AS9100 are in the process of trying to figure out…
Donald J. Wheeler
In the 1940s the War Production Board trained approximately 50,000 individuals in how to use process behavior charts (also known as control charts). At that time the computations were done by hand, and the emphasis was on making things as easy as possible for those doing these computations. As a…
