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The Staggering Costs of Health Insurance ‘Sludge’
Edmund Andrews
Seems everybody has a horror story about health insurance: Kafkaesque debates with robotic agents about what is and isn’t covered. Huge bills from a doctor you didn’t know was “out of network.” Reimbursements that take months to process. It’s no secret that healthcare in the United States is…
150-percent Bills of Material Are Hurting Your Business
Scott Heide
During the last several decades, the ability to manufacture customized products for customers has become increasingly attractive to a growing number of companies. However, customization has led to manufacturers drowning in a sea of increasingly complex bills of material (BOM). Standard products…
Webinar Preview: Managing Change in a Digital Transformation
Quality Digest
Digital transformation is the integration of technology into all areas of a business, which fundamentally changes how organizations operate and deliver value to their customers. But what does success look like in a digital transformation? Project is on time and budget? Stakeholders are engaged…
Respect As a Lean Agile Lens
Jim Benson
Respect is an abused word. Weak minds use it as a placeholder for fear. Weak egos will demand it up front. Weak hearts will use it to attach themselves to people of bluster, wishing they could be so outspoken. We could do with a few more conversations about respect. We can see here, sadly, that…
Less Wasteful Laser Cutting
Adam Conner-Simons
Laser cutting is an essential part of many industries, from car manufacturing to construction. However, the process isn’t always easy or efficient. Cutting huge sheets of metal requires time and expertise, and even the most careful users can still produce huge amounts of leftover material that go…
Relationships As a Lean Agile Lens
Jim Benson
When we work together, which we all do, everything involves relationships. People request work from other people... that is a relationship. People take jobs that involve bosses and structure... those are relationships. People form teams to get specific types of work done... again, relationships.…
A Postmortem on Product Management
Ayman Jawhar
Product management as we’ve known it up until now—as a limited function or role—is effectively dead. However, viewed as a culture, product management is thriving. I predict “product culture” will be central to the future of work in digital economies. Yet knowledge workers, executives, and business…
What Are Lean and Six Sigma? Part 3
Gregg Profozich
Welcome to the third installment of our series on lean and Six Sigma. As we saw in the first article, lean and Six Sigma are complementary continuous improvement methodologies that reduce the overall waste and variability, respectively, in production processes. The second article went into some…
What Is Your True Cost of Quality?
James Wells
When is a product “good enough” to accept? This is the classic challenge of quality. High customer expectations demand that suspect products be thoroughly scrutinized and a high standard set for their release. Customers expect this, and quality staff strive to achieve it. The other side of the tug…
The Cost of Bored Industrial Engineers
Andrew Schutte
Industrial engineers design, develop, test, and evaluate integrated systems for managing industrial production processes. Functions include quality control, human work factors, inventory control, logistics and material flow, cost analysis, and production coordination. These and other facets are…
Benefits of Workflow Automation in B2B E-Commerce
Yoav Kutner
Like business-to-consumer (B2C) e-commerce, business-to-business (B2B) e-commerce allows customers to purchase parts and supplies via an online portal. The difference is that in B2B e-commerce, both the customers and suppliers are businesses, and the customers may or may not be the end users of the…
Wonderful
Bruce Hamilton
At the tender age of 21, living in a universe with far too many parallels to present day, I took a job—which turned out to be more than a job—to support myself in college by working as a caregiver, cook, driver, and constant companion to a man who as a young adult had been infected by the awful…
Getting a Grip on What’s Next for Robotics in Manufacturing
Andrew Peterson
Manufacturing robotics is to some extent following a similar path of advances to those in machining and fixed automation systems. Though the ROI is most easily measured in efficiency and cost savings, manufacturers are looking for robotic technology to help them resolve a pain point in their…
First Permitted 3D-Printed House to Hit the Market
Ryan E. Day
‘For sale: 3 bd, 2 ba, 1,407 sq ft home in Riverhead, NY,” the groundbreaking listing on Zillow reads. “Own a piece of history! This is the world’s first 3D-printed home for sale [on the open market]. The future begins with this historic property!” Perhaps the exclamation marks are warranted.…
Are Lean Supply Chains Responsible for Shortages?
Ashley Y. Metcalf
Lean supply chains are designed based on several key principles. First, the general philosophy of lean is to reduce or eliminate nonvalue-added waste. The concept of reducing waste is always beneficial to organizations. We should continuously strive to reduce things like wasted time, wasted effort…
What Are Lean and Six Sigma? Part 1
Gregg Profozich
The manufacturing world, across industry sectors, has witnessed significant improvements in productivity and competitiveness during the past couple of decades as a result of continuous improvement (CI) methodologies. Two of these methodologies that are recognized as having broad applicability are…
If Pandemic Productivity Is Up, Why Is Innovation Slowing Down?
Knowledge at Wharton
A new study finds that productivity has remained stable or even increased for many companies that shifted to remote work during the coronavirus pandemic. However, innovation has taken a hit as both leaders and employees feel more distant from each other. Businesses tend to spend less money and…
What Are Lean and Six Sigma? Part 2
Gregg Profozich
In the first article of this series, we saw that Lean and Six Sigma are complementary continuous improvement methodologies that reduce the overall waste and variability in production processes, respectively. Although these two methodologies use different approaches and tools to drive improvements…
Looking to the Future
Bruce Hamilton
As we begin to take our approximately 4 1/2 billionth trip around the sun, I’m reflecting on the previous 525,600 minutes and looking ahead to the new decade. The decade (the ‘20s), by the way, began last month, not a year ago, a factoid noted in a short address by Hiroyuki Hirano in 1999 as the…
Communications As a Lean Agile Lens
Jim Benson
We focus on the work, we focus on the teams, but we rarely focus on the individuals. What does an individual professional need to be fully engaged, enthusiastic, and ready to take on new challenges? Think of five of those needs. At the core of any needs you wrote down is bound to be information.…
How to Turn Plastic Waste in Your Recycle Bin Into Profit
Joshua Pearce
People will recycle if they can make money doing so. In places where cash is offered for cans and bottles, metal and glass recycling has been a great success. Sadly, the incentives have been weaker for recycling plastic. As of 2015, only 9 percent of plastic waste is recycled. The rest pollutes…
Galileo’s Telescope
Steven Ouellette
What is the most important thing for your business to be working on right now? Would everyone else working there agree? Is everyone working toward the business’s goals? How do you know? Most businesses in my experience cannot answer these questions. There may be metrics, but they are not…
Problem Solving With Manufacturing Data
Jay Arthur—The KnowWare Man
There are two ways to increase profits: increase sales or reduce costs. Although most data analysis seeks to find more ways to sell more stuff to more people, addressing preventable problems is an often overlooked opportunity. Preventable problems consume a third or more of corporate expenses and…
10 Tips to Avoid Making Your Projects As Painful As a Root Canal
Michelle LaBrosse
Do you find the idea of having to do project management almost as much fun as getting a root canal? If so, you’re not alone. But it doesn’t have to be as bad as a painful dental procedure to adopt more effective ways of managing your projects. Nor does it have to be extremely boring or some type…
Making Smart Thermostats More Efficient
MIT News
Buildings account for about 40 percent of U.S. energy consumption, and are responsible for one-third of global carbon dioxide emissions. Making buildings more energy-efficient is not only a cost-saving measure, but also a crucial climate-change mitigation strategy. Hence the rise of “smart”…

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