The International Organization for Standardization has developed more than 17,000 international standards on numerous subjects. For medical device companies, the most important of these standards is ISO 13485, which provides internationally recognized guidelines pertaining to quality management…

Harley-Davidson knows how to build ownership. For decades, the motorcycle company has attracted and retained a client base that shows no signs of waning. People purchase its products without solicitation, and collectively they gladly spend millions of dollars to wear its advertising on clothes,…

I read an article in Wired magazine the other day that got me to thinking about the relationship between statistics, engineering knowledge, and theory. The article claimed that with the era of massive data storage and analytical capabilities, the scientific concept of the “theory” was becoming…

As the skilled, baby-boomer workforce nears retirement, years of technical expertise is exiting as well. Factories are watching years of knowledge leave their organizations, and how to replace these skilled workers has manufacturers concerned. In a 2008 survey of 100 senior manufacturing…

Question: Many modern enthusiasts claim that feng shui is Chinese for the practice of arranging objects (such as furniture) to help people achieve their goals. What is the American corporation translation of feng shui? Answer: 5S (5 = feng, S = shui) A very good client (definition: one in…

I received an interesting piece of junk mail recently. What caught my attention and provoked me to open it was simply that it was from an overseas automobile manufacturer and my lean obsessiveness engaged. I know this manufacturer isn’t necessarily using the Toyota production system, but I…

            Abbreviations t Thickness of stack of product T Batch average of t sampled in the hour Ta Average if batch averages T…

A recent conversation with the general manager of a manufacturer that was in the process of implementing lean methodologies provided insights as to their ongoing results. He was excited about what was happening in his company. Initiatives in the past had not been successful, and he now understood…

A few months back, I wrote about the choices an organization makes regarding its quality management system (QMS). At that time, I talked about the overall system, with particular focus on management’s investment and support. Today I’d like to spend some time talking about the choices within the…

Have you ever sat in a meeting room continually looking at your watch and counting the minutes left before the meeting ends? Have you wondered why—after 20 years of manufacturing similar products—you’re still discussing the same issues that reduce your profits and stunt your growth? Did you…

Walk into many stores and you’re bound to be impressed by the quality of digital cameras, TVs, cell phones, and other consumer electronics. Every year the quality of these devices improves by leaps and bounds, and consumers often pay less as products improve. I wish the same could be said about the…

The price of petroleum fuels has affected attendance at regional manufacturing expos by quality professionals. Gasoline pump prices are past $4 per gallon, and national trade shows are feeling the effect. Conferences, seminars, and national trade shows aren’t necessarily deficient, but quality…

To be a good leader, you must develop people who can function without you looking over their shoulder. There’s no greater satisfaction than mentoring someone who turns out to be a great leader. In war, a leader must develop capable people to carry out orders, and to succeed in business you must as…

Are great leaders born or made? I believe leadership is a trait that can be learned. To be a leader you must have followers and you must develop people that can go out and function without you looking over their shoulder. I believe there’s no greater satisfaction than to be able to mentor someone…

In September 2007 at the QuEST Forum I had the privilege of presenting an AT&T in-house Six Sigma process-improvement success story, “Reducing Non-Billed Inside Wire Dispatches,” which was selected as a best practice in the Six Sigma category. (QuEST—Quality Excellence for Suppliers of…

As is the case with any lean implementation in a traditional environment, culture change is the most difficult obstacle to success. A company can hire consultants, develop work teams, and begin lean initiatives, but if it only talks the talk, the initiative soon becomes just talk. Why do we do lean…

I was working with a client to create their business’s critical performance measures the other day, and one of the managers said, “We should set the target higher than we want it—you know, aim high to hit low.” This set off one of my rants, and I thought I would share it with you. When I worked as…

A few weeks ago, I found myself and my family on a beach making a sand castle. It was the last day of our vacation and shortly after we began working the warm South Carolina sand, an official approached us and asked if we would like to be contestants in the weekly sand sculpture contest. Why not?…

When my daughter, Anna, was in the fifth grade, her teacher asked the students to write down their personal goals. Anna’s goals are still displayed in our home, so we obviously feel that there was something special about this assignment. Not bad for a fifth grader, huh? Could you do better? How? Is…

In June 2007, the U.S. Food and Drug Administration issued the dietary supplement current good manufacturing practice (CGMP) final rule (21 CFR Part 111). In essence, the final rule requires that the proper controls be in place for dietary supplements during manufacturing, packaging, labeling, and…

In the last couple of months, two topics have become particularly vexing to me. First, how can we be environmentally responsible by purchasing E85 fuel when there are few service stations that provide this new elixir? Second—even more difficult to comprehend—why do companies eliminate products and…

We examined the practices and major problems that can easily occur in the use of balanced scorecards in the June 3 issue of InsideSixSigma. Now let’s look at why attention to causal event analyses can improve the future performance of any process. Often, this traditional method fails to make metric…

Walk into many stores and you’re bound to be impressed by the quality of digital cameras, TVs, cell phones, and other consumer electronics. Every year the quality of these devices improves by leaps and bounds, and consumers often pay less as products improve.I wish the same could be said about the…

We examined the practices and major problems that can easily occur in the use of balanced scorecards in the June 3 issue of InsideSixSigma. Now let’s look at why attention to causal event analyses can improve the future performance of any process. Often, this traditional method fails to make metric…

In September 2007 at the QuEST Forum I had the privilege of presenting an AT&T in-house Six Sigma process-improvement success story, “Reducing NonBilled Inside Wire Dispatches,” which was selected as a best practice in the Six Sigma category. (The QuEST Forum—Quality Excellence for Suppliers of…