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Bruce Hamilton
In 1987, shortly after I became a manufacturing manager, the shop foreman at the time warned me about a young assembler. “Watch out for Michael,” the foreman said. “He tends to bend the rules. You may need to talk to him.”
In fact, I did watch Michael, and it did appear that he approached his…
Patrick Runkel
Did you ever wonder why statistical analyses and concepts often have such weird, cryptic names? One conspiracy theory points to the workings of a secret committee called the International Committee for Sadistic Statistical Nomenclature and Numerophobia (ICSSNN), which was formed solely to befuddle…
Brian Maskell
Companies that are seriously pursuing the lean journey soon find their accounting, control, and measurement systems need to change to support the new strategy. The principles and methods of lean thinking and practice are quite different from traditional business and therefore require different…
Kevin Meyer
“If you are too obsessed with success, you will forget to live. If you have learned only how to be a success, your life has probably been wasted.” —Thomas Merton, Love and Living
Sometimes there are dots just waiting to be connected....
I was rather surprised when Pope Francis mentioned Thomas…
Brian Maskell
I work with companies that are serious about being lean organizations. Most of them use lean accounting. It’s not about changing your accounting system. It’s about embracing lean principles and methods. Lean changes the way people look at management accounting. Here are 10 things to think about.…
Bill Kalmar
My wife Mary has an obsession—she always checks the expiration and freshness dates on food products that we purchase. Mary also marks purchase dates on products such as ketchup, mustard, and salad dressings when she places these items in our refrigerator. I think she has an expiration date on me…
George Chemers, Patricia Cronin
Although information is readily available about applying team-building techniques to Six Sigma projects, there’s not much about how learning styles affect the success of Six Sigma teams. Knowing that the “people side” of an otherwise technical and statistical-based methodology is important to a…
Mike Micklewright
Finally... the new version of ISO 9001:2015 has been released. I can hear many of you screaming, “Hurray!” Or not. More realistically, I’m sure many of you living in the kaizen world are thinking, “Yeah, so what? This stuff has nothing to do with real kaizen, and in fact, it often creates…
Bob Emiliani
During the early days, late 1970s to late 1980s, there existed just a few small organizations to help people learn about and implement Toyota’s production system (TPS). They were led by people with decades of hand-on practice at Toyota and its affiliated companies. Some organizations, however,…
Taran March @ Quality Digest
As a sort of character-building exercise, I recently opened an unsolicited email from my health insurance provider. I was intent on doing a quick purge of sham, spam, and flimflam, and I figured this one would be no different. But I also know I’m biased against health insurers, so I decided to set…
Matthew Barsalou
I gave a rather successful talk on communicating design of experiments (DoE) at the recent ENBIS 14 conference in Linz, Austria. Things went mostly well, but it’s also fair to say many attendees had one major criticism: I didn’t explain why one factor at a time testing (OFAT) isn’t ideal. That…
Bob Emiliani
There are many ways to improve your thinking skills. One way is by practicing critical thinking. Teachers require their students, from elementary school on through college and graduate school, to do research to gather information, analyze the validity of data, determine the strengths and…
Barry Johnson
The adage “if you aren’t moving forward, you’re falling behind” is true more often than not. Regardless of the type of business, all organizations need to improve to survive. The last words uttered by managers in failing organizations are, “We’ve always done it this way.”
The key to long-term…
Donald J. Wheeler
The best analysis is the simplest analysis that provides the needed insight. Of course this requires enough knowledge to strike a balance between the needed simplicity and unnecessary complexity. In parts one and two of this series we looked at the properties of Weibull and gamma probability…
Ryan E. Day
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Mike Micklewright
I mean it! If your company can’t master 5S, try “1S” and stop! Stop the entire lean transformation until 5S is mastered in at least one process-focused area of the facility.
It’s a tremendous waste for a company to spend thousands, if not millions, of dollars on a “lean transformation” only to…
Dan Somers
As a person working in quality manufacturing, it’s probably in your DNA to look at a quality challenge and choose Six Sigma or something similar as the framework for getting to the answer. It’s also likely that you’re spending a lot of time gathering and analyzing data, applying hypothesis…
Darin Marcuz, Laron Colbert
This article describes a novel approach to calculating the financial aspect of overall equipment effectiveness (OEE), with the result referred to as $EE (as in monetary units). By using $EE, a management team readily can “SEE” their operation in financial terms. Employees are then better able to…
Eston Martz
When we take pictures with a digital camera or smartphone, what the device really does is capture information in the form of binary code. At the most basic level, our precious photos are really just a bunch of 1s and 0s, but if we were to look at them that way, they'd be pretty unexciting.
In its…
Mike Richman
Of all the tools in the lean toolkit, 5S is the one that has proven to be the most effective—and also the most elusive. It’s effective because the actions needed to sort, set in order, shine, standardize, and sustain mirror the deeper, critically important philosophy of thinking about value, waste…
Donald J. Wheeler
Story update 9/8/2015: There was an error in the data set for columns "Skew" and "Kurt" in figure 7. The error has been corrected.
Clear thinking and simplicity of analysis require concise, clear, and correct notions about probability models and how to use them. Last month in part one we looked…
Mike Micklewright
You’ve heard of Bam Bam, Duran Duran, Zsa Zsa, so-so, tutu, and Reverend Tutu. And now we have... Gemba Gemba! But what is Gemba Gemba?
Quite simply, Gemba Gemba means going to the gemba for the purpose of observing others going to the gemba to ask, teach, learn, coach, and challenge. In this way…
Bob Emiliani
As both a participant and witness to the practice of lean management in higher education, I’d like to point out methodological errors in relation to how lean is practiced in industry.
People in industry who practice lean management correctly provide us with a standard to which we can compare the…
David Schwinn
I recently had a dream in which Adrian Bass, a colleague and friend for whom I have much admiration, asked me why I still care about quality management after all these years.
You can substitute Six Sigma for quality management because, in my mind, they are both part of a larger belief system that…
Fred Schenkelberg
Just, please, plot the data if you have gathered some time-to-failure data, or you have the breakdown dates for a piece of equipment. Any data really. It could be your review of your car maintenance records and notes and dates of repairs. You may have some data from field returns. You have a group…