There are two ways to increase profits: increase sales or reduce costs. Although most data analysis seeks to find more ways to sell more stuff to more people, addressing preventable problems is an often overlooked opportunity. Preventable problems consume a third or more of corporate expenses and profits.

Data analysis can pinpoint problems and eliminate them forever. Problem solving with data is a much more reliable and controllable way to cut costs and increase profits. Sadly, few people know how to do this consistently.

How do you solve operational problems with 100-percent success rate? Take out the guesswork. The vast majority of improvement projects involve reducing or eliminating defects, mistakes, and errors. If you have raw data about when the defect occurred, where it happened, and what type of defect it was, you can create a world-class improvement project that eliminates the guesswork. And you can do it using a tool you most likely already have: Microsoft Excel.

Burning plastic cart carrying a fax machine, a laptop computer, and a three-ring binder. Click here for larger image. Credit: FCD/NIST

Several centuries ago, scientists discovered oxygen while experimenting with combustion and flames. One scientist called it “fire air.” Today, at the National Institute of Standards and Technology (NIST), we continue to measure oxygen to study the behavior of fires.

Any number derived from real observation is made up of three components. The first of these is the intended signal, the “perfect” value from the object being observed. The second is error (or noise) caused by environmental disturbance and/or interference. The third is bias, a regular and consistent deviation from the perfect value.

O = S + N + B, or observation equals signal plus noise plus bias

The signal usually is predictably constant, as is the bias. Identifying and eliminating bias requires a set of techniques beyond the scope of this article, so for the remainder of this, we will consider both as components of the signal, leaving a somewhat simpler equation for our observation.

O = S + N, or observation equals signal plus noise

This article focuses on removing the random noise component from the observation and leaving the signal component. The noise is in the form of chance variation, which sometimes enhances the signal and sometimes detracts from it. If we could separate the noise from the signal and eliminate it, our observation would be pure signal, or a precise and consistent value.

Augmented reality (AR) means adding objects, animations, or information, that don’t really exist, to the real world. The idea is that the real world is augmented (or overlaid) with computer-generated material—ideally for some useful purpose.

Augmented reality has been around for about 30 years. But it’s only during the last five years or so that it has been widely used on mobile devices. If you have wondered why your new iPhone 12 has a LiDAR depth sensor, the answer is, in part, for augmented reality. Almost all modern phones now have depth sensors for AR. LiDAR makes depth sensing more accurate.

Unlike virtual reality (VR), AR on mobiles requires no special equipment. There’s no need for headsets or handheld devices. All you need is your mobile phone.

More than fun and games

Although games are probably the most notable use of AR on mobiles (Pokémon Go is a good example), there are business and training applications as well. Perhaps the simplest AR business application is labeling real-world objects. Google Maps, for example, recently launched Live View, adding real-world labeling of objects and directions via the mobile phone’s camera. Real-world objects, when viewed through the mobile phone, can show added text, objects, or 3D animations. Live View has all of these.

On Sept. 29, 2020, the recorded worldwide death toll from Covid-19 reached 1 million. Six days earlier the United States reached 200,000 Covid-related deaths. So how did the United States with only 4 percent of the world’s population manage to capture 20 percent of the world’s deaths in this pandemic?

The 19 countries listed in figure 1 account for 85 percent of the Covid-related deaths worldwide, as reported by the European CDC. Here we can see how the U.S. death toll exceeds all others.

 
Figure 1: Number of Covid-related deaths reported by 19 countries as of Sept. 26, 2020

The short explanation for this dubious achievement is that between April 1 and the present, the United States had an average of 27 percent of the worldwide total number of confirmed cases of Covid-19. With that kind of market share, the high death toll was sure to follow. But a more detailed answer requires that we look at the number of deaths per capita and the rate at which these death tolls are growing.

The idea of digital transformation can be scary. The growth of technology is outpacing a comfortable pace of adoption for many manufacturers. But remaining content with the status quo often means being left behind. Digital transformation has become an imperative to give manufacturing organizations the flexibility and agility required to overcome business disruptions and adapt to rapidly changing and demanding global markets.

Digital transformation of quality management is a process that depends on something you already have: quality data. Your quality management system is key to optimizing all your quality operations, including supplier and materials management, production processes, quality checks, packaging, and shipping.

InfinityQS calls this holistic approach “manufacturing optimization.” It starts with improving the way you use data to answer the strategic, big-picture questions that truly matter to your business.

Limits of the status quo

The barriers to transformation are often a result of operational and resource challenges that typically boil down to one thing: everyone’s plate is already full. Whether managing and maintaining servers and IT projects, or running day-to-day production, no one has the time to take on new transformation projects.