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Kevin Meyer
To many people, lean manufacturing was invented in Japan and is synonymous with the Toyota Production System (TPS). They will tell you that the TPS is the manufacturing philosophy that enabled Toyota to effectively conquer the global automobile market by reducing waste and improving quality. While…
Joel Bradbury
One of the most important goals of lean manufacturing is the elimination of waste. Taiichi Ohno, father of the Toyota Production System (TPS), defined three categories of waste: mura, muri, and muda. While muda is the most widely known, muri and mura are equally important to understand.
Muda
Muda…
Gwendolyn Galsworth
One of my favorite sayings is, “Nothing changes if nothing changes.” The reverse is also true: If nothing changes, nothing changes. Perfect! So I was more than a little surprised recently when I visited a company that had made a sizeable investment in bringing continuous improvement into the…
Bruce Hamilton
Most often when we think of a wheel, it’s in the context of transportation, one of the more obvious and ever-present of the 7 wastes in lean. In fact, the first likely use of a wheel and axle was not for transport but for processing—actual work.
According to the Smithsonian, the potter’s wheel…
Roger Jensen
For several decades, manufacturers have been pursuing lean on their shop floors to reduce costs and improve lead times through waste elimination and process improvement. They have been less successful, however, in reaping lean’s potential benefits in their purchasing, planning, and supply chain…
Christopher Martin
Recently, during one of my many adventures across the internet, I stumbled across a photo that struck me. It depicts an aisle of a U.S. drugstore, where nearly every single product facing has a tag on it announcing a price and a limited-time promotion. The entire row is covered with bright yellow…
Bruce Hamilton
Here is an article I wrote 10 years ago, recently resurrected from the lost letter file. I can’t remember why I wrote it or for whom. Originally titled, “What is Kaizen?” the article still resonates with me as I hope it will with you.
My study of TPS has been guided by book learning, tacit…
Tim Lozier
When it comes to quality management, it’s not just about the requirements. As companies register to ISO 9001:2015, we see an additional shift. Not only are management system requirements changing to build an improved framework for the standard, but we also see an emphasis on an overall mindset…
Harish Jose
As our new year unfolds, I wanted to write an article to remind myself of three pieces of advice. They are from Epictetus (55–135 AD), Marcus Aurelius (121–180 AD), and George Pólya (1887–1985). Epictetus and Aurelius are two famous Stoic philosophers of the past, and Pólya is a famous Hungarian…
Jim Benson
If you are reading this, you are likely human. Congratulations; I’m human, too.
Everyday we all wake up and wonder what the day will bring. We wonder who we will meet, what conversations we will have, and what we will do.
We all want to do things
In business we have processes, we have…
Matthew Muller
I have been inspired to write this article after learning about Joseph Juran and understanding the effect he has had on our society. I started working at Juran Global about six months ago, and since then I’ve had several friends and past colleagues reach out to me with questions like, “What is…
Kevin Meyer
Often we become so focused on fixing problems and resolving issues that our entire sense of reality shifts. We begin to live in a bubble that encompasses the negative and blocks the positive. Because they demand our attention, the negative aspects of work and life consume a disproportionate amount…
Paul Naysmith
If you have ever used Maslow’s hierarchy of needs out of context, and especially as they relate to motivation in the workplace, I will track you down and tape you to a lamppost with a sign around your neck explaining your major error. Maslow’s theory dates back to ideas from the 1940s, and…
Gwendolyn Galsworth
The barracuda is an ambush fish, capable of speeds of 25 mph and feared by all but killer whales and sharks. If confronted by one of those enemies and there is no place to hide, the barracuda simply attacks. Whether hunting or escaping, the barracuda is a formidable predator.
I find myself…
Kyle Pheland, Belinda Jones
Change is inevitable in every organization. Planned or not, forces inside and outside the enterprise can sometimes encumber a workforce and lead to nonvalue-added processes. Growing spurts, major technology implementations, or even small supply-chain organizational projects can present more issues…
Bruce Hamilton
While holiday shopping at one of my favorite food places, Johnson’s Popcorn, I came upon a scene reminiscent of our lean training video, Toast Kaizen. After I placed my order for 18 one-gallon buckets of caramel corn for friends and family, the Johnson’s kitchen shifted gears from mail-order sales…
Harish Jose
The Forth Bridge is a famous railroad bridge in Scotland and is more than 125 years old. It needs painting to fend off rust. Albert Cherns, the late famous social scientist who founded the Department of Social Sciences at Loughborough University, identified the Forth Bridge principle as part of…
Evan Miller
Sponsored Content
Like many manufacturers, boat maker Smoker Craft has enormous amounts of data. The challenge, according to Quality Assurance Manager Dave Frey, was that all the data were on paper. All these bits and pieces of paper filled dozens of filing cabinets. Many man-hours were devoted to…
Mike Richman
In the quality profession today, the term “guru” tends to be thrown around with reckless abandon, more often than not self-referentially by the “guru” him- or herself. Don’t get me wrong; there are many outstanding people now working in our field, with interesting and perhaps even revolutionary…
Kevin Meyer
“Excellent firms don’t believe in excellence—only in constant improvement and constant change.”—Tom Peters
The plan-do-study-act (PDSA) cycle is the core component of continuous improvement programs. You may have heard it called the plan-do-check-act (PDCA) cycle—and they are very similar—but I…
Andy Henderson
This is the third part in a series about my perspective of what the future has in store for various aspects of manufacturing. I approached each aspect by imagining what is possible using what we know to be technically possible today. In part one I covered cutting tools for machining and in part…
Mike Richman
Hard as it may be to believe, a close analysis of our extensive trove of behavioral data on the Quality Digest user group indicates that more than a handful of you don’t regularly watch our regular weekly web TV show, Quality Digest Live, which broadcasts from our studio in Northern California…
ASQ
Sponsored Content
When flood waters ravaged portions of Colorado in September 2013—killing crops, inundating homes, and buckling many miles of roadways—countless federal, state, and municipal government workers sprang into action helping citizens. State and federal government agencies spent…
Gwendolyn Galsworth
In a visual workplace, information is converted into simple, universally understood visual devices and installed in the process of work itself, as close to the point of use as possible. The result transforms a formerly mute work environment into one that speaks, eloquently and precisely, about how…
Andy Henderson
In my last article about the future of cutting tools, I discussed a vision and road map that I created by imagining what a manufacturing ideal might look like using what we know to be technically possible today. Here, I’m going to describe a vision for a futuristic production management system…
