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How Automakers Can Think Like a Disruptor
I t wasn’t that long ago that GM ran commercials advertising that its Oldsmobile division didn’t just produce cars for your grandfather, but also for everyone else. It was an attempt to reinvent the brand’s staid image—and it didn’t work. Now, the Oldsmobile division and its iconic vehicles are…
Coal to Solar: Retraining the Energy Workforce
As more coal-fired power plants are retired, industry workers are left without many options. There is a light at the end of the tunnel, though. In a new study published in Energy Economics, researchers from Michigan Technological University and Oregon State University offer hope for coal workers…
Eight Reasons Why Your Design Controls and Risk Management Processes Fail
Design controls and risk management processes should be tools to ensure that medical devices are designed, developed, and manufactured to be safe and effective, and to address indications for use, too. All too often, however, design controls and risk management are viewed as a pile of “stuff”…
Be Aware of Your Blind Spots
“Honest feedback is hard to take, especially from a relative, a friend, an acquaintance, or a stranger.” —Franklin P. Jones I once found myself needing to find new employment. The situation that I was leaving had been complex, to say the least, and I worried that perceptions of failure would dog…
Pressure Points for Physicians in Healthcare Transformation
The HORNE Healthcare team has been blogging recently about the necessary business model changes we think are inevitable to healthcare transformation. We’ve focused on the macro level, urging healthcare organizations to take action. Although I believe our advice is sound for large systems, I am…
From Print to Patina
Best described as “a museum of art being built,” the Polich Tallix Fine Art Foundry in Rock Tavern, NY, has helped artists develop and produce their work for nearly 50 years. Large-scale Frank Stella statues adorn the exterior of the premises, which is otherwise unassuming in all but scale. The…
Asking the Right Questions About Statistics
Approaching the end of the school year means focusing on graduation rates, dropout rates, and other data suggesting trends for students. Opportunities for considering statistics abound, but one must examine the way that these statistics are actually used by asking the right questions about the…
Eye of the Beholder
Many moons ago, when I was just getting started on my lean journey, I visited a large automotive supplier to benchmark pull systems. My own factory had started a pilot kanban between two work centers and I was hoping to gain some insight from a more experienced source. To my disappointment, when…
How to Determine the Worst Case for a Process
How do you determine the “worst case” scenario for a process? Is it by assuming the worst case for each process task or step? No. The reason is that the probability of every step having its worst case at the same time is practically zero. What we’re looking for is a value that will occur a very…
Puzzling Over Performance
In a recent post, I examined the differences in productivity across small and large manufacturing firms, and noted that there were differences across manufacturers in terms of size. But it’s also clear from the literature that productivity differs across companies even in the same industry. Why…
Are You a Human or a Robot?
A couple weeks ago, I wrote a post about emotionally unavailable customers. Hat tip to James Lawther for inspiring me to actually flip the tables here and think about emotionally challenged employees, instead. The question I posed in response to his comment on that post was: Why do we transform…
Low-Cost and Lightweight
An improved titanium alloy—stronger than any commercial titanium alloy currently on the market—gets its strength from the novel way atoms are arranged to form a special nanostructure. For the first time, researchers have been able to see this alignment and then manipulate it to make the strongest…
American Manufacturing Is Globally Competitive
How competitive is American manufacturing? By the year 2020, the United States is projected to take the top spot in the Global Manufacturing Competitiveness Index (GMCI), a multiyear research platform from Deloitte and the Council on Competitiveness. The 2016 GMCI surveyed more than 500 of the…
Fault Tree Analysis and Its Common Symbols
A fault tree analysis (FTA) is a logical, graphical diagram that starts with an unwanted, undesirable, or anomalous state of a system. The diagram then lays out the many possible faults, and combinations of faults, within the subsystems, components, assemblies, software, and parts comprising the…
Finding Freedom as a Project Manager
Ihave studied systems dynamics modeling for three decades. What I’ve experienced first-hand is that when you establish several key core values, you can create an entire self-replicating system for your organization. I experimented with this idea first with Cheetah Learning, where our three core…
When Online Customers Block Your Product
ISO 9001:2015, Clause 4.2—“Understanding the needs and expectations of interested parties” requires the organization to determine the “requirements of these interested parties that are relevant to the quality management system.” When customers block an organization’s content, it is a sure sign…
Building a Culture of Prevention, Part 1
More than 313 million global work-related accidents occur each year, according to the International Labour Organization, with a high percentage of those accidents resulting in significant time away from work. Each accident bears a personal and financial cost for the worker and the employer. Yet,…
How Can Hospitals Possibly Prepare for Disasters?
The tragic shooting in Orlando brought dozens of victims to emergency rooms. Even now, several of those people are still clinging to life. Many across the nation are praying for them and the other victims. Without quick response and high-quality emergency medical care, many more than the 49 already…
Suggestions for Writing Standard Operating Procedures
Standard operating procedures, or SOPs, are critical to quality assurance. Frequently, in an operation with many associates, each one does his or her job as well as possible (because no one wants to do a bad job). Some people, however, will do tasks differently than others—and usually they think…
How Things Break—and Why Scientists Want to Know
Humans spend a lot of time creating things, and these activities drive a huge amount of our lives, economically and personally. We’re always in a fight to keep our creations from breaking down. Houses, roads, cars. Power lines and bridges. Solar cells and computers. Batteries. People. Then there…
Combating the ‘Cult of Busy’
More than one-third of Americans say they don’t have enough time in their day to get things done, and the majority of Americans who report not having enough spare time also say they battle stress, reports the Johns Hopkins Health Review. Busyness is a badge of honor for those who equate a packed…
The Matrix: It’s a Complex Plot
Remember the classic science fiction film The Matrix? The dark sunglasses, the leather, computer monitors constantly raining streams of integers (inexplicably in base 10 rather than binary or hexadecimal)? And that mind-blowing plot twist when Neo takes the red pill from Morpheus’ outstretched…
The FDA Forms New Partnerships to Ensure Product Safety
Globalization is posing challenges for public health. For the U.S. Food and Drug Administration (FDA), part of that challenge is the ever-increasing volume and complexity of FDA-regulated products coming to America’s shores. In fiscal year 2015, there were more than 34 million shipments of FDA-…
Regenerative Companies Will Own the Future
Each generation experiences significant change due to innovations, disruptions, and shifting perspectives. These transform our ways of operating and organizing in business and beyond. Yet, it seems we’re now living in a particularly dynamic period, with metamorphic shifts that challenge what we do…
The Science Behind Great Product Design
Back in 2004, I was saddled with a two-hour commute to work almost every day. Fortunately, I had something with me to make the experience more bearable: my new third-generation iPod. Many of you probably remember your first iPod experience, how great it was to carry your entire music library in…

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