All Features
Loic Sadoulet, Thomas Hinterseer
It’s a tragic irony that the day before the 2010 Deepwater Horizon oil well disaster, executives from BP and the rig’s operators, Transocean, visited the platform on a “management tour” that included a number of specific safety-related purposes.
During the tour, there were already signs that all…
Bruce Hamilton
I wrote a piece a little more than five years ago about a variety reduction program (VRP), an amazing but little-known product-design optimization tool. At the time I referred to VRP as an idea whose “time had not yet come.” Last week, as I gave a short presentation on VRP, I realized that five…
Donald J. Wheeler
Story update 10/9/2023: This article is a corrected version. The earlier version suffered from a programming error that affected all of the PID results.
Many articles and some textbooks describe process behavior charts as a manual technique for keeping a process on target. For example, in Norway…
Frank Townsend
World shipping changed forever when the Panama Canal opened on Aug. 15, 1914. It was an engineering marvel of its day, cutting the distance required to get from the Pacific Ocean to the Atlantic by as much as 8,000 nautical miles.
The shipping industry is changing once again as 70 heads of state…
Gillian Groom
You often hear the data being blamed when an analysis does not deliver the expected answers. I was recently reminded that the data chosen or collected for a specific analysis is determined by the analyst, so there is no such thing as bad data—only bad analysis.
This made me think about the steps…
Henry Zumbrun
There has been some misunderstanding about the intent of ASTM E74—“Standard practice of calibration of force-measuring instruments for verifying the force indication of testing machines.” When it was written back in 1974, the standard’s intent was to establish calibration traceability back to…
Stanford News Service
For Melissa Valentine and her colleagues at Stanford, the future of work is here: “flash teams” of skilled professionals who have probably never met before and may work on different continents, but who can turn a napkin sketch into a product within days or weeks.
Valentine, assistant professor of…
Knowledge at Wharton
I t wasn’t that long ago that GM ran commercials advertising that its Oldsmobile division didn’t just produce cars for your grandfather, but also for everyone else. It was an attempt to reinvent the brand’s staid image—and it didn’t work.
Now, the Oldsmobile division and its iconic vehicles are…
Jon Speer
Design controls and risk management processes should be tools to ensure that medical devices are designed, developed, and manufactured to be safe and effective, and to address indications for use, too.
All too often, however, design controls and risk management are viewed as a pile of “stuff”…
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…