All Features
I have long admired and respected Toyota. I have been to its factories, published and written books and articles about its revolutionary production system, known many of its brilliant people, and taught its methods to thousands of students. Like many of Toyota's admirers, I was shocked and saddened…
Steven Ouellette
With the announcement of another Toyota recall, it seems that everyone and their dog have an opinion about Toyota, and some of them might even be drawing the right conclusions. While everyone is allowed to have opinions (not the dogs—on quality matters I don't trust entities that consider cat poo a…
PQ Systems
In the world of continuous improvement, it might seem that one does not want to look back. After all, as systems improve, old data is no longer useful, and keeping it around—like keeping old love letters—may someday get you into trouble.
Knowing when to recalculate control limits is important, as…
Pierre Huot
If a manufacturer were to ask its clients how they evaluated goods or services, the three most common metrics would be goods at a fair price, on-time delivery, and quality. Ask which could be most valuable and in all likelihood the most significant response would be quality. When included in the…
Bill Hathaway
While eating my lunch at the park last fall, I looked down at the wooden deck below me, and noticed that an ant had picked up a large crumb from my sandwich. The crumb was heavy, and the ant labored to move it. Unfortunately, the gap between the deck planks was too wide for the ant to cross…
Donald J. Wheeler
Last month’s column looked at how to fix some of the Problems with Gauge R&R Studies. This month I will show you how to learn more from your gauge repeatability and reproducibility (R&R) data with less effort. Rather than getting lost in a series of computations, the "evaluating the…
Mark R. Hamel
My teenage education was (maybe) enhanced by substantial doses of Monty Python. Occasionally, I discover a lean metaphor somewhere within their body of work. One of my absolute favorite scenes is from the movie, Monty Python and the Holy Grail. The three-minute scene goes by two names: “The…
I was a 30-year-old quality project manager on a continuous metal processing line. We coated metal for a broad range of consumer and industrial products. Just like many metal-processing facilities, particularly back then, we used a bunch of processes involving chemistry of varying evilness for a…
Christopher Sirola
Many years ago, I was flipping through stations on the radio and came across a talk show. I don’t remember the topic of discussion, but something the host said stuck with me.
“Scientists,” the host blustered (and I paraphrase), “are 95-percent confident of these results! Wow!”
The sound you’re now…
William A. Levinson
Six Sigma has been credited with six- or even seven-figure returns in single projects, but it has not kept the manufacturing jobs of its principal exponents—Motorola, General Electric, and Maytag—in the United States. Henry Ford, on the other hand, proved that lean manufacturing can make almost any…
Barbara A. Cleary
A young man in PQ Systems' hometown survived a dramatic auto accident last summer in which police-captured video footage of his spectacular, airborne vehicle was broadcast throughout the nation. That was just the beginning of his problems, for during his hospitalization, his medical records were…
Steven Ouellette
After my last column citing some really bizarre flaws in how our brains perceive reality, I thought I might cover some flaws in logic that are applicable in the world of quality. So, basically, even if our brains are working correctly, we can still send our Black Belts off on false trails trying…
The emergence of cargo cults on some Pacific Islands after World War II is an amusing and oft-repeated story.
The relatively simple lifestyles of these islanders were interrupted by Japanese aircraft dropping large supplies of clothing, medicine, canned food, and tents to support the Japanese…
Bill Waddell
I got one of those mass e-mails the other day, the ones with inspirational stories promising good luck and eternal salvation, provided you forward it to 10 people immediately. I chose to delete it and take my chances with the Almighty, betting that He was not really a party to an agreement linking…
Bruce Hamilton
A colleague, friend, and lean leader in health care related a story awhile back that I think is worth sharing. Joanne Marqusee, COO at Hallmark Healthcare System, was standing in line at a grocery store checkout. While she waited, Joanne recalls, she noticed that the cashier had added an unusual…
Minitab LLC
(Minitab: State College, PA) -- Swiss-based Metalor Technologies, a global leader in precious metals and advanced materials, is a supplier to electronics companies and manufacturers of medical and electrical equipment.
Metalor’s skill in creating reliable technology has earned the company a…
Donald J. Wheeler
Measurement error is ubiquitous. As a result, over the past 250 years, different areas of science and engineering have come up with many different ways to deal with the problem. One approach to the problem of measurement error was developed during the 1960s within General Motors. Throughout the…
Bruce Hamilton
A couple years ago, I was consulting in a large rolling mill to help reduce late deliveries to its customers. After walking the floor for the first time with an enthusiastic 20-something engineer (let’s call him Mark), I asked for help with observation at a particular point in the factory where…
A new year always brings new hope, new plans, and new perspectives. While looking ahead is the most direct route to progress, looking back is essential to understanding the present. After all, the past creates the consequences that will shape the future.
With this in mind, the editors of…
Akhilesh Gulati
A friend recently returned from a visit to China; his company had been acquired by a Chinese organization and he had gone there as part of the mutual due diligence. Not only did he come back impressed by their lower manufacturing costs but also with their technological advancements. While we in…
Donald J. Wheeler
In my July column, “Where Do Manufacturing Specifications Come From?” we found that the intraclass correlation coefficient is the natural measure of relative utility. This measure is theoretically sound and easy to explain. This column will look at how to use the intraclass correlation to…
Minitab LLC
ResMed is a global manufacturer of medical devices. The company’s products help people with sleep-disordered breathing (SDB) and other respiratory disorders. Characterized by the interruption of normal breathing patterns during sleep, an estimated 18 million people in the United States suffer from…
Barbara A. Cleary
Signs in factories or on the back of long-range trucking rigs sometimes proclaim “X days since our last accident” or “No on-the-job injuries since 1964.” Extending the stretch between such accidents may be motivated by this announcement alone, but there are better ways to diminish or prevent…
Davis Balestracci
You know what the third-quarter review meeting means: a packet will be handed out with bar graphs and, no doubt, trend lines on each of about a zillion “key performance indicators” that show:
• This month vs. last month vs. 12 months ago (maybe year-to-date as well)
• The three months’…
Minitab LLC
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efore Michael Mercer established his consulting company, he accumulated more than 30 years of quality improvement experience at 3M. That experience led him to develop a deep trust in the power of Minitab Statistical Software. He began using one of the earliest mainframe computer versions to…
