All Features
Lauren Dunford
Industry 4.0 has been a hot topic for years now, for good reason: 86 percent of manufacturing C-suites say digital transformation is a priority, and about 91 percent of industrial companies are investing in digital factories. Yet Industry 4.0 has also become a buzzword in many ways, as so many…
Bruce Hamilton
With GBMP’s 18th annual Northeast Lean Conference on the horizon, I’m reflecting on our theme, “Amplifying Lean—The Collaboration Effect.” The term collaboration typically connotes an organized attempt by unrelated, even competitive, parties to work together on a common problem; for example, the…
William A. Levinson
Inflation has skyrocketed during the first half of 2022, which also saw a sharp downturn in the stock market in response to the Federal Reserve’s increase in interest rates to reduce demand. This resulted in a bear stock market and raised the prospect of an economic recession. The nonpartisan…
Del Williams
Food processors have long sought a safer, more energy-efficient means to convey product with less spillage, breakage, or downtime due to necessary cleaning and maintenance. Although tubular drag conveyors have offered these desired attributes compared to belt, bucket, or pneumatic systems, many in…
Richard Harpster
On Dec. 7, 2021, Ford Motor Co. updated its IATF 16949—“Customer specific requirements” (CSR), which require the use of reverse FMEAs (RFMEA) on new equipment (“tooling”). The first sentence of the reverse FMEA requirement reads: “Organizations are required to have a process in place that ensures…
Jeremy L. Boerger
You may not be familiar with the term “information technology asset management” (ITAM), but most businesses deal with it on a regular basis (for better or worse). ITAM is what helps control the costs of computers, servers, software, and services used to create the computing environment modern…
Kevin Ketels
The conditions that led to a shortage of baby formula were set in motion long before the February 2022 closure of the Similac factory tipped the U.S. into a crisis.
Retailers nationwide reported supplies of baby formula were out of stock at a rate of 43 percent during the week ended May 8, 2022,…
Albert Rees, Joe Vernon
The pandemic had many consequences for manufacturing companies, the most prevalent being supply chain disruption. In light of these disruptions, it is paramount that organizations establish robust and reliable operations to ensure productivity targets are met—especially as consumer demands continue…
Donald J. Wheeler
Many different approaches to process improvement are on offer today. An appreciation of the way each approach works is crucial to selecting an approach that will be effective. Here we look at the problem of production and consider how the different improvement approaches deal with this problem.…
James J. Kline
Big data is a relatively new phenomenon. Its use is increasing in many organizations. But, as with many new processes, its use cuts both ways. It has positive benefits to both the organization and customers. It also has its potential downside. This piece looks at both with respect to the quality…
Brandon Cornuke
Manufacturers work hard to minimize disruptions to their operations and invest significant resources to minimize production risk. They also are under constant pressure to find new ways to deliver more value to their customers. Sustainable business growth is critical to delivering this value. Many…
Emily Newton
There’s no better time than now. As a species, we need to mitigate the effect we have on our planet. There are many ways to do this—namely, through green and eco-friendly initiatives—but one sector is having the biggest impact of all: the industrial and manufacturing sector. In the 2010s, the…
Harish Jose
T he dictum, “purpose of a system is what it does” (POSWID) is famous in cybernetics, attributed to the management cybernetician Stafford Beer.
Beer notes: “A good observer will impute the purpose of the system from its actions and thus from the resultant state.”
Hence the key aphorism and acronym…
Donald J. Wheeler
Students are told that they need to check their data for normality before doing virtually any data analysis. And today’s software encourages this by automatically providing normal probability plots and lack-of-fit statistics as part of the output. So it’s not surprising that many think this is the…
Bruce Hamilton
In 1985, about the time I was discovering there was a better way to produce products, The Natural, a film about an aging baseball player with extraordinary talent, was garnering multiple Academy Awards. This archetype concerning natural “God-given” abilities is common in Western culture—in sports…
Brittney McIver
At some point, every medical device company will encounter an issue that requires an internal investigation. Whether it’s due to a nonconformance, complaint, CAPA, or an audit issue, you’ll have to conduct a failure or root cause investigation to pinpoint why the issue occurred in order to resolve…
Knowledge at Wharton
Negotiating a salary increase or a job promotion ranks high on the list of hard conversations to have at work, and it doesn’t get any easier without a plan.
“People think, ‘I’m just going to knock on their door, sit down with them, and noodle around and see where this goes.’ That’s not a plan,”…
William A. Levinson
Ryan Day1 describes how the rise of independent auto dealers is a “gray swan” event for the automobile industry. This was not only bound to happen, as observed by the author, but also long overdue. The article states, “...current state laws prohibit OEMs from selling new vehicles directly to…
Bruce Hamilton
The level of excitement was high in our machine shop as we drew closer to our goal of less than 9-minute changeovers on the BNC lathe. (See Part One of this story for how we got there.) Setup improvements had so far reduced changeover time to 20 minutes, cutting the economic order quantity from…
Jonathan Gilpin
The world of procurement is often tricky. It involves choosing one appropriate candidate, ultimately benefiting them while rejecting and disadvantaging others.
That said, it isn’t just the businesses picked that will profit from winning the contracts; it’s also their supply chain, their local…
Bruce Hamilton
We had been working with the Toyota Production System Support Center (TSSC) for two years to build a model line in our assembly department. As we moved from small batch production to one-by-one, the results had been astounding: Customer lead time reduced from two weeks to one day, crew size cut in…
Scott A. Hindle
In 2010, new to the world of statistical process control (SPC), I was intrigued by Don Wheeler’s statement that “No data have meaning apart from their context” (from his book, Understanding Variation—The Key to Managing Chaos, SPC Press, 2000, available on Amazon). For a while, I didn’t really get…
V R Vijay Anand
As the world moves toward a new, post-pandemic normal, industries must leverage digital transformation at an accelerated pace. This is already happening. According to IBM, 67 percent of manufacturers have accelerated digital projects since Covid-19.
Although improved operational efficiency is…
Bruce Hamilton
Every February, there are welcome reminders that spring is on the way. The first for me is a witch hazel bush in my front yard that defies subfreezing weather to produce fragrant yellow flowers. Then, a few weeks later, crocuses and winter aconites will emerge from the snow. The cycle continues…
Donald J. Wheeler
Last month we looked at analyzing observational data. Here we will consider experimental data and discover a weakness in the way they are obtained that can contribute to the problem of nonreproducible results.
Background
The discipline of statistics grew up in agricultural and biomedical research…