All Features
Thomas R. Cutler
Food quality and safety are priorities for consumers, and from Hazard Analysis and Critical Control Points (HACCP) to the Bioterrorism Act to lot traceability, food manufacturers are responding. Reputations and brands are at risk when safety concerns and product recalls are front-page news. There…
Thomas R. Cutler
Food quality and safety are priorities for consumers, and from Hazard Analysis and Critical Control Points (HACCP) to the Bioterrorism Act to lot traceability, food manufacturers are responding. Reputations and brands are at risk when safety concerns and product recalls are front-page news. There…
Craig Cochran
A few years go I had the good fortune of doing some consulting with B&C Specialty Products in Hopeulikit, Georgia. B&C does light manufacturing, primarily plastic molding and assembly, and they also distribute imported products produced by companies in the Far East. They have about 150…
Michel Podevyn
In the old days at Soliant LLC in Lancaster, South Carolina, employees pushed 275-lb drums filled with acrylic resin powder to a scale for weighing and adding to a mix. Once the powder was weighed out, two employees manually scooped 1.5 lb at a time from the drums to the mixing vessel, the…
Bill Kalmar
Recent department store sales figures in the Wall Street Journal are interesting and intriguing. Despite a slow economy in parts of the nation and frigid February weather in some states where several retailers experienced a decrease in sales, some high-priced retailers had exceptional results. What…
Mike Micklewright
Question:What do you call a root cause analyst?
Answer: A whys guy!
I had been summoned from my Chicago suburban home and office to visit a company in Wisconsin—Land of Cheese—to discuss the possibility of providing some lean training requested by the director of operations, Brent Favor. This was a…
Thomas R. Cutler
More than 13 hours per week creating documents and nearly seven hours per week organizing documents are common among small and midsize engineer-to-order (ETO) manufacturers; four hours per week are spent managing document routing and another 10 hours per week searching for information. All this…
Thomas R. Cutler
More than 13 hours per week creating documents and nearly seven hours per week organizing documents are common among small and midsize engineer-to-order (ETO) manufacturers; four hours per week are spent managing document routing and another 10 hours per week searching for information. All this…
On December 29, 2006, passengers of American Airlines’ Flight 1348 were confined in a parked aircraft for eight hours. By this time, “The toilets on the American Airlines jet were overflowing. There was no water to be found and no food except for a box of pretzel bags.” This fiasco was…
William A. Levinson
On December 29, 2006, passengers of American Airlines’ Flight 1348 were confined in a parked aircraft for eight hours. By this time, “The toilets on the American Airlines jet were overflowing. There was no water to be found and no food except for a box of pretzel bags.” This fiasco was…
Craig Cochran
Last year I had the good fortune of doing some consulting with B&C Specialty Products in Hopeulikit, Georgia. B&C does light manufacturing, primarily plastic molding and assembly, and they also distribute imported products produced by companies in the Far East. They have about…
Bill Kalmar
This column normally originates from the hammock in the woods behind our home. With almost a foot of snow on the ground, though, this month’s contribution would better be titled “Thoughts From a Lounge Chair in My Den.” So, while sitting in my favorite chair and listening to the popping of…
Bill Kalmar
This column normally originates from the hammock in the woods behind our home. With almost a foot of snow on the ground, though, this month’s contribution would better be titled “Thoughts From a Lounge Chair in My Den.” So, while sitting in my favorite chair and listening to the popping of…
Kevin Meyer
Established in 1903, the Harley-Davidson Motor Company grew rapidly during the two world wars. Foreign competition hit the industry early, and by 1953 Harley-Davidson was the last remaining major motorcycle manufacturer in the United States. Harley was bought by AMF in 1969 and by the late…
Thomas R. Cutler
Dairy plants are among the heaviest users of municipal water in the United States, using two gallons of water for every gallon of consumer product produced. The clean-in-place (CIP) systems that daily wash and sanitize every truck, tank, pipe and surface in the plant use the greatest amount of that…
Thomas R. Cutler
Dairy plants are among the heaviest users of municipal water in the United States, using two gallons of water for every gallon of consumer product produced. The clean-in-place (CIP) systems that daily wash and sanitize every truck, tank, pipe and surface in the plant use the greatest amount of that…
Craig Cochran
Last year I had the good fortune of doing some consulting with B&C Specialty Products in Hopeulikit, Georgia. B&C does light manufacturing, primarily plastic molding and assembly, and they also distribute imported products produced by companies in the Far East. They have about…
Bill Kalmar
Have you noticed that the airwaves no longer carry informative, unadulterated news anymore? “Breaking News” has become the standard, thus all news is presented in an excited, almost breathless, tone. We at home now question the urgency of any segment, particularly when we discover that a cat…
Thomas R. Cutler
The hiring practices of manufacturing companies have become increasingly lean. The old processes of advertising, screening, interviewing, hiring and training are riddled with waste; it’s both too expensive and extremely time-consuming. The hiring shift to staffing companies has become increasingly…
Thomas R. Cutler
The hiring practices of manufacturing companies have become increasingly lean. The old processes of advertising, screening, interviewing, hiring and training are riddled with waste; it’s both too expensive and extremely time-consuming. The hiring shift to staffing companies has become increasingly…
Rick Ringlespaugh
A tier-two automotive supplier faces the challenge of interacting with customers and original equipment manufacturers (OEMs) on many different programs. For each of more than 100 programs the company is involved in, it must submit a detailed quality plan and then be prepared to change the plan as…
Nicholas Muthuri
Lean was initially started in manufacturing and production departments, and various efforts are being made to apply its principles in service industries. In a highly industrialized world spurred by high technological changes, businesses are forced to change their strategies to a more lean way…
Mike Micklewright
In the past several months, registrar auditors strongly recommended to three former or current clients that they develop and install turtle diagrams for each of their processes. Two auditors from one registrar actually taught a former client how to develop a turtle diagram during a surveillance…
Bill Kalmar
Those of us in the acting profession hear those words regularly at the end of a particularly grueling day from a director attempting to extract perfection from a group of actors. (I’ll discuss my own celluloid exploits later).It’s appropriate to utter similar words at the end of 2006—a grueling,…
Douglas C. Fair
If you read my previous two columns, you’re well educated on the top 10 mistakes that manufacturers make when implementing statistical process control (SPC). Several of these mistakes are indicative of what I call the “check-box mentality.” This mentality is typically the result of an…