Lean

AI has amazing capabilities, and it’s one of the best technologies for the future. It’s helping to change the world and bringing productivity enhancements across industries with its exceptional use cases. Quality assurance isn’t left out, either. AI is highly useful in any product development…

Many organizations have decided to automate their quality management system (QMS) or upgrade their currently automated QMS. Quality management tends to involve significant numbers of documents, which automated systems are especially efficient at creating, accessing, tracking, updating, and…

When an issue arises, it’s important to take quick action. Whether that means launching a software patch, pulling a batch, or halting the use of a reagent, it’s critical to tackle the immediate problem.

But just as critical as “How do we fix this?” is “How do we make sure this…

Many organizations list continuous improvement (CI) as a priority, but it often fails to take root in day-to-day work. It appears as a workshop or a one-off initiative, then fades without lasting change. If the goal is long-term performance and sustainable growth, CI can’t be incidental or…

Capturing real-time data in all areas of the business is vital for maintaining long-term success. When manufacturers conduct business with separate systems, data end up in silos, and information can’t flow in an efficient manner. This prevents smooth coordination of data between people and…

A recent company meeting revealed what management called a “handoff problem.” The sales team would close deals, then toss them over the wall to the service team, which would promptly fumble the relationship because they didn’t understand what had been promised or why the customer bought in the…

In manufacturing, the term connected worker has quickly gone from emerging concept to executive mandate. As companies grapple with turnover, skill gaps, and increasing complexity, the urgency to modernize frontline work has never been clearer.

…

Most negotiations have an opening bid. That bid becomes the anchor that the rest of the negotiation centers upon. If you’re good at setting anchors—and avoiding being anchored to a number you won’t like—you’ll get more out of your negotiations.

An interesting dynamic that can…

Imagine this: A production line hums along smoothly. Operators clean and check equipment between cycles to spot problems before they snowball. No scrambling. No surprises. That’s what autonomous maintenance looks like.

It’s a concept born from the principles of total productive…

Small to midsize manufacturers are facing mounting pressure from unpredictable supply chain disruptions. From fluctuating customer demand to reshoring operations and diversifying suppliers, maintaining efficiency and protecting cash flow have never been more critical.

Global…

In October 1989, my company hosted Total Improvement Process Week, one of the most productive experiences of my career. Our consultant was Ryuji Fukuda, a Deming Prize winner and author of Managerial Engineering (Productivity Inc., 1983), a book I still value for its emphasis on management’s…

It’s called “work” for a reason. Most days we’re able to “work” through it and find enjoyment in what we do. But occasionally we’re faced with a grind that saps our strength and threatens to derail us. Fortunately, there are simple techniques for working through that grind.

I love…

In this article I’m looking at the notion of organizational purposes in light of cybernetic constructivism. The ideas here are inspired by giants like Stafford Beer, Spencer Brown, Ralph Stacey, Werner Ulrich, Russell Ackoff, and Erik Hollnagel.

The corporate world seems to be…

The plant manager’s day started perfectly. The production schedule was optimized, the teams were aligned, and the shift was running smoothly. Then, a critical pump on Line 3 failed. The floor supervisor tried to radio for maintenance, but his call dropped in the plant’s notorious dead zone. By…

Quality initiatives rarely fail because of bad tools. They fail because people don’t adopt them.

Organizations spend months mapping processes, running kaizen events, or documenting corrective actions, only to watch the improvements unravel when employees quietly return to the “old…

There’s a lot of talk about automation these days, not just in manufacturing circles but also the news in general. As the demands of modern manufacturing grow more complex, and manufacturing industries continue their digital transformation—with automation playing an ever-expanding role—where…

Software selection, implementation, and ongoing maintenance are critical stages in the life cycle of biomedical software systems such as asset and calibration management platforms. Yet few industry resources provide detailed, practical guidance for managing these processes effectively.

…

It’s hard to balance all the demands that are placed upon you as a leader. Many of us default to dysfunctional ways of spending our time and energy. If you know what the common mistakes are and take a more deliberate approach to investing your time and energy, you’ll get better results from your…

In my Labor Day article, “Celebrating Our Frontline Scapegoats,” I observed that of the seven wastes, the one most people recognize is defects. This is understandable: Workers are often blamed for defect-causing situations over which they have little or no control. This article continues that…

A vital concept from the chemical process industry, management of change (MOC) relates primarily to safety. It means that whenever we change a factor in a cause-and-effect diagram (e.g., machine, material, manpower, method, measurement, environment, or any other factor), we create risks of…

Organizations often face a familiar dilemma: It’s not a shortage of good ideas, but a struggle to decide which one to pursue first. During project prioritization meetings, leaders are likely to present a wide range of perspectives. The finance team pushes for hard savings, while operations…

Everybody wants to have good measurements. To this end, many recommend a regular schedule of recalibration. While this sounds reasonable, it can actually degrade the quality of the measurements.

The key to getting the most out of a measurement process is to know when to…

Cutting costs is nothing new in manufacturing. What’s new is having to do it while juggling labor shortages, supplier delays, and tighter customer demands. Lean principles such as reducing waste and optimizing workflows still matter, but they’re no longer enough on their own. Staying competitive…

After a couple of heart attacks, I’ve learned to eat much healthier. But finding snacks can be challenging once you remove Doritos and Cheetos from the equation. A good substitute for me is now Harvest Snaps, which are baked lentil pods. I highly recommend the tomato-basil version.

Driving home from a customer last week, I caught a glimpse of a digital billboard—the kind that flashes eight different ads per minute. From a cost and aesthetic perspective, these backlit displays are a big step up from the old paperhanger versions. But I wondered: What do drivers actually see…

Uncertainty often pushes manufacturers to slow down. Orders fluctuate, budgets tighten, and “wait and see” becomes the default strategy. But a growing number of companies are taking the opposite approach, using slowdowns as windows to invest in digitalization and automation.  

…

In several articles about challenges for tomorrow’s quality leaders, we’ve addressed how to plug the knowledge drain and effectively manage your company’s know-how. Your organizational structure and processes can be your worst enemy—or best asset. Organizational silos and roadblocks can impede…

They may seem simple, but SOPs (standard operating procedures) are surprisingly tricky. On the surface, they describe how a specific process is carried out at your organization. Pretty straightforward, right?

In reality, there are a lot of requirements for writing a good SOP, and…

For today’s manufacturers, quality is no longer just a box to check; it has evolved into a strategic pillar central to company success. Once a tactical process focused on meeting regulatory standards, it now plays a leading role in a company’s profitability, brand reputation, employee safety and…

With Labor Day coming around, here’s an article to celebrate the folks who usually get blamed for the quality problems.

Not surprisingly, when people first learn about lean’s seven wastes, the one they find most relatable is defects. They might not immediately grasp the concept of…

Want to build your team? Get rid of the people who are on it. I don’t mean go about firing people in a flurry. Become what I call a “net exporter of talent.”

You need to develop your people to the point that they’re ready for new challenges. Build their skills. Make them more…

I’m exploring one of the most fascinating aspects of Heinz von Foerster’s work: his complete rejection of philosophical labels and -isms. Von Foerster, the Austrian-American physicist and cybernetician, in his later years didn’t want to be pinned down by any single philosophical position. This…

Global-scale events have tested the bounds of supply chain systems. The coronavirus, for example, made it clear how critical an efficient supply chain is for continuity and survival. It’s a real-world example of how important it is to have an enterprisewide system that uses a quality management…

Let’s start with the argument every aspiring leader loves to have, even if they don’t say it out loud:  Specialist or generalist?  Depth or breadth?  That’s the fork in the road every ambitious leader eventually hits. And the farther up the ladder you go, the more that question lingers.

I recently needed to have a hot water expansion tank installed in my house. The first plumber who came to mind is widely advertised on local radio. The company’s online reviews suggest that they do good work, but one added that they are expensive—and it’s probably because they have radio ads…

I took a walk-jog this morning, something I’ve been doing pretty regularly since early June. Some days are better than others, and today started out sluggish. But as I turned the corner of my street, my neighbor drove by, rolled down his window, and gave me a friendly wave.

Almost…

The engineer came into the statistician’s office and asked, “How can I compare a couple of averages? I have 50 values from each machine and want to compare the machines.”

The statistician answered, “That’s easy. We can use a two-sample t-test.”

“How would that work?” asked…

Although patient safety is paramount in healthcare settings, about 1 in 10 patients is harmed in healthcare, and more than 3 million deaths occur due to unsafe care, says the World Health Organization (WHO). The reality is hospitals and healthcare facilities face numerous challenges in managing…

Complacency won’t show up on a control chart. But its damage is real. Can AI and systems thinking help us detect it and respond before trust is lost?

As customer expectations evolve, one question remains: Are customers still at the core of your company’s operations?

Back in…

Quality Digest attended the 2025 Hexagon Live event in Las Vegas in June—and with that came the opportunity to speak with the great minds, creators, innovators, and sales teams of Hexagon. Darren Metherell, head of sales at Hexagon, followed up with the QD team after this event to speak more…

Did you know that shutdowns, turnarounds, and outages (STOs) can consume up to 50% of a plant’s annual maintenance budget? That’s according to a report by the Boston Consulting Group.

STOs are among the most complex and high-stakes events in industrial operations. They’re costly,…

The European Union has taken a leading role in shaping a variety of data and AI regulations. One of its most recent initiatives, the Ecodesign for Sustainable Products Regulation (ESPR), extends this regulatory momentum into the manufacturing sector. Under this new regulation, manufacturers and…

These are new times for manufacturers. Global pandemics. Worldwide supply-chain disruptions. Steep price increases for parts and materials. Increasingly competitive global markets.

Manufacturers are can-do people, but doing becomes harder in today’s “do more with less”…

Facility teams are constantly balancing urgent repairs, preventive tasks, asset tracking, and compliance, all while ensuring smooth day-to-day operations. But when processes are manual, fragmented, or unclear, even simple tasks can spiral into delays, miscommunication, and wasted time.

…

Health systems across the country are unknowingly paying multiple times for the same medical equipment—once to own it, and again to rent it. The issue isn’t always an increase in clinical demand; it’s often availability and visibility to medical device inventory. The cost of these unnecessary…

The corrective and preventive action (CAPA) process is one of the most important elements within a medtech company’s quality management system (QMS). The goal of the CAPA system is to identify, address, and prevent systemic issues that could compromise product safety, regulatory compliance, and…

Ever had that moment when a project seemed crystal clear during a meeting, only to find out weeks later that everyone had completely different interpretations? It’s like playing a grown-up version of the “telephone” game  where what starts as “We need this done by the end of the week” ends up…

Most days we walk through life unaware of the conversations occurring around us. And then there are those times you overhear a conversation that stops you dead in your tracks. You have to hit rewind in your brain and ask, “Did they actually just say that?”

Ever have one of those…

Many companies are still clinging to paper-based and unconnected electronic processes, despite the clear disadvantages. Without modern tools like QMS software, these organizations risk compromising product quality, falling behind in compliance, and ultimately losing competitive ground.

…

I love passionate people—people who throw themselves into their work with every last bit of energy they have. To them, everything about their work is important. It’s serious business, and they drive hard to form the world in an image they’re proud of.

However, with passion comes…

The advanced semiconductor material gallium nitride (GaN) will likely be key for the next generation of high-speed communication systems and the power electronics needed for state-of-the-art data centers.

Unfortunately, the high cost of GaN and the specialization required to…

The storm isn’t coming: It’s already here, and many leaders are realizing they’re sailing without instruments. The current business climate is a storm of volatility, uncertainty, complexity, and ambiguity. Strategic plans become outdated overnight. Decision-making feels like a risk. And yet…

A global food safety and quality certification, BRCGS (British Retail Consortium Global Standards) initially focused on food safety but now comprises various sectors such as packaging, consumer products, and retail. It aims to ensure that businesses maintain high standards of safety and quality…

The world has shifted in remarkable ways, and flexible work is an undeniable force reshaping professional life. But do remote and hybrid arrangements help the environment or lead to unintended consequences? A new study by Mark Ma at the University of Pittsburgh, Betty Xing at Baylor University,…

Tom Taormina, CMC, esteemed quality consultant and long-time contributor to Quality Digest, has passed away. He is survived by his wife, Midge, and their three children. Recently, Taormina was working with Quality Digest and a consortium of others to design a certified training program for…

For decades, Six Sigma has been the gold standard in process improvement—a proven methodology for reducing defects, improving yield, and driving measurable operational gains. It delivered tremendous value in manufacturing, healthcare, and financial services. But in today’s shifting business…

When quality failures go public, it’s not just your product on the line—it’s also your reputation, compliance status, and workforce morale.

From product recalls to OSHA citations, recent manufacturing disasters reveal a brutal truth: The real cost of outdated documentation isn’t…

For as many words as we use, we’re terrible communicators. Voicemails are jumbled streams of consciousness. Emails are “text bombs” with no rhyme or reason. Presentations are nothing but crippling piles of slides. But don’t worry—here are three rules of three to make your communications clearer…

Remote work has become a game-changer for older individuals with disabilities, offering a solution that not only improves their employment prospects but also brings substantial economic benefits, according to a new study from the Center for Retirement Research at Boston College.

…

Amid uncertainty in manufacturing, AI adoption, labor market fluctuations, and salary disparities across industries and geographic regions, quality professional compensation can be difficult to calculate. Without current job-level salary benchmarks, quality professionals, from technicians to…

The cornerstone of efficient industrial and facility management, maintenance, repair, and operations (MRO) cover all activities related to equipment maintenance, procurement, upkeep, and inventory management. This includes spare parts, consumables, lubricants, cleaning supplies, safety equipment…

For many hundreds of years, “If it ain’t broke, don’t fix it” has summarized the predominant approach to process operation. From the physician’s admonition to do no harm, to the slightly more positive aphorism that the squeaky wheel gets the grease, there is a common theme of differentiating…

I am a longtime admirer of George Spencer-Brown’s “Laws of Form.” In this article, I explore how his notion of reentry helps illuminate the paradoxes and blind spots in modern ideologies, especially the rise of xenophobia and extreme nationalism. These rigid ideologies depend on distinctions…

There’s an old army saying, “No plan survives first contact with the enemy.”

I’m sure some Navy or Marine guy out there will attribute this comment to their branch of service, but to be clear, it came from the Army.

Actually, the original of this paraphrased quote is widely…

When I talk with maintenance leaders, I hear urgency. Pressure is mounting. They’re being asked to cut costs, attract skilled workers, and embrace AI—and fast. Yes, pressure turns coal into diamonds. But constant pressure can wear down even the best teams. So for our 2025 State of Industrial…

Last year, after many years of physical therapy, cortisone shots, and experimental treatments to prop up my failing knees, I decided to go bionic and get full knee replacements. Holding out hope for more than a decade that emerging cell-therapy technology would offer breakthrough cartilage…

In the early 2000s, at my former company, my team was tasked with creating educational products for a major national educational toy brand. We developed an impressive line of learning tools—forensic kits, microscopes, telescopes—designed to engage curious young minds. After securing coveted…

In today’s competitive manufacturing landscape, resilience is the new quality. And one of the most powerful lessons in resilience doesn’t come from a factory—it comes from an art form.

In the Japanese tradition of kintsugi, a broken ceramic bowl is not discarded or disguised. It’s…

One of the key findings in Greenlight Guru’s 2025 Medical Device Industry Report was that economic uncertainty is playing a large role in the decisions medical device companies make this year.

The report surveyed more than 500 medical device professionals across quality,…

In a professional kitchen, no chef prepares a steak, a cake, and a casserole simultaneously with all the ingredients scattered across the counter. There’s a method: one recipe at a time, with only the ingredients needed for that specific dish.

The same principle applies to how we…

A few months ago I visited a potential customer, a high-tech startup, which like many Boston-area tech companies is developing astounding products that would have been considered science fiction only 10 years ago. The parking lot was half full at 8 a.m., but the entrance was locked to visitors,…

Every day, quality leaders face a variety of production and process issues. Although some problems are easy to fix, others require deeper investigation, such as using a 5 Whys analysis or fishbone diagram. But then there are the stubborn, recurring issues that can lead to quality issues,…

The Chinese character for crisis means “danger” and “opportunity,” and tariffs have created a supply chain crisis throughout the United States. Paul Roberts of the Seattle Times reports that fewer ships are arriving in Seattle: “Fewer ships coming into the U.S. means companies can’t get…

When we step into a complex organization—whether in manufacturing, healthcare, or finance—we often find ourselves navigating a sea of competing truths. Everyone seems certain they see the problem clearly. Yet somehow, solving it feels harder than it should.

Why?

Often, it’s…

Occupational health and safety (OHS) is often brushed aside as a checkbox exercise—something assigned to compliance officers or forgotten in day-to-day operations. But this mindset comes at a cost. Every year, millions of people suffer injuries, illnesses, or worse, simply because their…

Uploading something “to the cloud” has become common enough that most people are acutely aware of the storage advantages of cloud services—whether in their personal or professional lives—as well as how they might benefit administrators in any business. What might surprise people is the…

A little enjoyment is always important. I recently read a blog post titled 15 Facts That Will Make You Laugh.

A few of those facts were:
• There is a Welsh town with a 58-letter name:
Llanfairpwllgwyngyllgogerychwyrndrobwllllantysiliogogogoch.
• You used to be able…

We humans love to complicate things. The more crap we hang off of a product, the better we think it is. The more engineering that goes into it, the more we can sell, right?

Wrong.

Simplicity wins. Every time. (iPod, anyone?)

As an entrepreneur, I get to hang out with…

Define, measure, analyze, improve, control, goes the mantra used to carry out improvement projects in many companies. In various books, these steps get slightly different interpretations. But the overall outline is still characterized by DMAIC. This article will show a proven way to simplify and…

In an earlier blog, I introduced you to Arnie Weimerskirch, a former vice president of corporate quality at Honeywell and the former chair of the Baldrige Judges Panel. I recently had lunch with him and learned how he got involved with the Baldrige Program and how it influenced his career. I…

Nobody likes change. I know if you do anything that changes my routine in the morning, my whole day is whacked. We all hate change. Heck, most of us hate getting change at the grocery store because of all those coins.

As a leader, though, your job is to get others to want to…

A question I’m getting asked a lot these days is, “What’s a quick way for me to improve my ability to focus?” I have several suggestions. One of the new ones I’m working on is connected to a principle from lean management. It’s called the 3S’s—Sweep, Sort, Standardize. See if it doesn’t have…

‘Every organization has countless opportunities for improvement, but only a few points—what we call constraints or bottlenecks—govern the pace and performance of the entire system,” says Rami Goldratt, who gave the closing keynote presentation at the Baldrige Performance Excellence Program’s…

The semiconductor industry is one of the most complex, dynamic, and technologically advanced sectors in the world. It plays an essential role in shaping modern life, serving as the foundation for everything from smartphones and MRI machines to kitchen appliances and space shuttles. In today’s…

Generative AI (gen AI) is fundamentally transforming industries, reshaping the way professionals innovate, create, and solve problems. These systems, capable of generating text, images, music, and complex solutions, aren’t just tools—they’re catalysts for a paradigm shift in the professional and…

Warehouses are the backbone of supply chains, ensuring that goods move efficiently from suppliers to consumers. However, the physical demands of warehouse work—heavy lifting, repetitive motions, and prolonged standing—can take a toll on employees, leading to fatigue, injuries, and long-term…

Email is the bane of our existence. Sure, it’s awesome for funny cat videos, chain letters, and getting awesome blogs like this one (see what I did there?), but it can also cause massive amounts of stress and waste tremendous amounts of time.

One of the first things I do when I…

Failure analysis helps uncover the root cause of equipment issues so you can fix problems and prevent them from happening again. This guide outlines a clear, six-step process to conduct effective failure analysis and write a report that adds long-term value.

Failure analysis…

Dr. Donald J. Wheeler has been one of Quality Digest’s most highly read authors for decades. His teaching on the use of control charts in industrial settings has long been considered the gold standard. He has conducted more than 1,100 seminars in 17 countries on six continents, and his books…

As director of quality at a manufacturing plant, James faced the reality of shift every day. As the plant embraced new technologies and adapted to changing global dynamics, he knew that quality management could no longer be reactive. The question was whether he could turn these shifts into…

What’s your favorite regulatory pitfall? I know that’s a strange question, but if you’ve spent much time in the medical device industry, there are likely a few that come to mind. People reach out to me all the time asking how to break into the medical device industry—and I love those…

Once hailed as both an ethical mandate and a strategic necessity after the upheaval of 2020, diversity, equity, and inclusion (DEI) initiatives now face intense scrutiny and pushback. Major corporations—ranging from Walmart to Google—are quietly retreating from these programs amid escalating…

The pharmaceutical industry and the medical device industry have unique ways of defining terms like deviation and nonconformance. Often, this leads to confusion about how events should be classified and managed.

This article explains the difference between a deviation and a…

Keeping quality high in today’s fast-moving production world is a big challenge. Traditional quality checks have worked well, but they can be slow, require a lot of work, and are prone to mistakes.

AI could change this by making quality control faster, more accurate, and easier to…

How do health and safety incidents affect your business? If a worker is injured or becomes ill, what kind of disruption does it cause? Is your productivity affected? What’s the effect on other workers in terms of workload or psychological health and well-being?

People are the…

Innovation is vital to the success of all businesses. Innovate or perish is the new mantra. Leaders must perpetually reinvent their processes, products, and services, because they typically have multiple competitors offering similar offerings. Only through innovation can most organizations…

Manufacturers face a critical challenge: capturing, standardizing, and scaling workforce knowledge. Skilled workers are retiring, and labor shortages are persisting. Outdated, paper-based documentation can no longer keep up. These methods create bottlenecks that slow productivity and make vital…

One transformative strategy that can revolutionize how organizations embrace generative AI  is peer mentoring. By leveraging the power of personal connections and shared expertise, peer mentoring accelerates learning, fosters collaboration, and fuels innovation. When mastering gen AI tools can…

Outliers are values that don’t “fit in” with the rest of the data. These extreme values are commonly considered a nuisance when we seek to summarize the data with our descriptive statistics. This article will show how to turn these nuisances into useful information.

The earliest…

Maybe you’re pulling reports from three different platforms, trying to reconcile numbers that don’t quite match. Maybe you’re manually copying and pasting from multiple spreadsheets, hoping you didn’t introduce any errors along the way. Or maybe you’re waiting on IT to clean up, prep data, and…

Some people don’t feel like they’re working unless their hair’s on fire. Somehow, they think it’s admirable to be feverish at a frenzied pace, breathless and full of urgency, turning tasks in record time and pushing the team to accelerate. Surely others will take notice and marvel at such hard…

Manufacturing is a fast-paced, constantly evolving, and dynamic environment, and the supply chain is at its heart. For small and medium-sized manufacturers (SMMs), navigating the complexities of the supply chain often feels like a high-stakes balancing act. From juggling fluctuating material…

A leader’s daily decision checklist is daunting: From hiring or firing to major business changes, every judgment call carries with it some level of risk. A bad choice could result in a toxic hire or a new product launch that crashes and burns. Perhaps more frightening is this: One poor decision…

This current job market is plagued by fake job postings that have been misleading American job seekers, wasting their time and distorting employment data. These deceptive listings—often created to collect résumés, inflate company growth metrics, or manipulate job market statistics—erode trust in…

We all have enemies. Some of us have many. But when we spend our time and energy focused on attacking them and counterattacking their inevitable strikes, we’re the ones losing. 

In getting us to attack, our enemy has taken us away from productive pursuits. They’ve hung a dark…

Established pharmaceutical facilities play a pivotal role in public health by ensuring the safety and efficacy of the medications they produce. This critical responsibility demands strict adherence to the Code of Federal Regulations, including 21 CFR 211.67—“Equipment cleaning and maintenance,”1…

In recent years, reshoring—the process of bringing manufacturing back to the U.S.—has gained momentum. Companies are reevaluating their offshore supply chains, driven by rising costs, geopolitical risks, and supply chain disruptions. For smaller manufacturers, this shift also presents a unique…

The Man of La Mancha never got to the unreachable goal—and if you’re being judged by overall equipment effectiveness (OEE), then your manager may also be dreaming an impossible dream. This column will look at problems associated with the use of OEE values.

OEE is a value often…

My story begins with Hurricane Milton, one of two tragic hurricanes to hit the west coast of Florida last year. Milton went right over Sarasota, where I live part of the year. It was a devastating storm; tree and plant debris still remain on the sides of many roads. Big root balls are still…

New research provides a compelling analysis of the repercussions of return-to-office (RTO) policies on employee turnover, hiring, and the overall talent pool within major corporations. Using data from more than 3 million LinkedIn profiles, Mark Ma, at the University of Pittsburgh, along with…

PharmaNZ is a family-owned nutraceutical company that manufactures health supplements for the world’s leading brands. The company produces more than 250 tonnes of powder-blend products, 10 million tablets, and 70 million hard-shell capsules annually for clients worldwide. The company, founded by…

Cash is king for manufacturers, from the owner down to the machine operators. If you visit any manufacturer, you’ll see that most have a keen eye on how everything is being used. Machines are generally only running if they are making parts; employees are typically only working if orders are…

I had just finished a keynote presentation and was at the book table set up by the client. Participants were invited to pick up one or more of my books, and the company would pay for them.

One excited audience member quickly made their way to the table and was perusing their…

Quality management has evolved far beyond traditional checklists and periodic inspections. For complex supply chains, quality is no longer a static endpoint. It’s a dynamic real-time process deeply interwoven with collaboration, transparency, and data-driven decision-making. As supply chains…

In last month’s article, “ANOVA and the Process Behavior Chart,” we saw how both techniques use the same basic comparison to answer completely different questions. Here, we’ll look at a case history where both techniques were used.

A physical property of a mass-produced item was…

Understanding the inner workings of your industrial artificial intelligence (IAI) system is crucial if you want it to add measurable value to your manufacturing operations. Here, we’ll dig into one important aspect of every AI: the inputs, aka your data. Including the right type and the right…

In global manufacturing, two key goals—intertwined yet distinct—heavily dominate the industry’s agenda: addressing the growing demand for environmentally sustainable practices, and optimizing operational efficiency. With these priorities in mind, companies are seeking multifaceted solutions that…

Today I’m looking at the free energy principle (FEP) by the British neuroscientist Karl Friston. The FEP basically states that to resist the natural tendency to disorder, adaptive agents must minimize surprise. This has implications for the gemba, as you’ll see.

A good example to…

In the ever-changing landscape of business management, the concept of quality has undergone significant transformations. What began as a focus on maintaining standards such as ISO 9001 and AS9100 is evolving into a more holistic approach encompassing organizational excellence. Tom Taormina’s…

Wharton management professor Peter Cappelli is routinely asked to predict the future of work. His expert answer is always the same: “The future looks like the past.”

He’s not trying to be cryptic. It’s just that the big changes ushered in by the pandemic five years ago are still…

Paul was sitting in his office staring at production numbers from the past quarter. Despite having a great team, strong customer demand, and state-of-the-art equipment, the factory’s performance wasn’t meeting expectations. There was a bottleneck in the assembly line—a critical chokepoint that…

I enjoy painting, and I’ll admit that I’m not the neatest painter out there—I get a lot on me. And I’m not the fastest painter either, but I feel like I do a pretty good job.  One of the tools that helps me improve my painting skills is painter’s tape (the blue stuff is my favorite). It enables…

We live in a world where problems aren’t just growing—they’re evolving into ever-more complex challenges. During the 20th century, we pushed the boundaries of innovation, creating complicated systems that demanded structured problem-solving approaches. Techniques like 5 Whys and the Ishikawa…

Audits and inspections are critical components of industrial safety management. These processes help organizations ensure compliance with legal requirements, identify risks, and improve workplace safety and operational efficiencies. Conducting regular audits and inspections is not just a…

In the world of operations and quality management, the pressure to act quickly can feel overwhelming. Senior executives are constantly racing against time to meet customer demands, solve problems, and keep shareholders satisfied. In the rush to address immediate challenges, “Ready, aim, fire!”…

In this article, I’m exploring complexity through the lens of George Spencer-Brown’s Laws of Form (Cognizer Co., 1994). This philosophical and mathematical treatise explores the foundations of logic and mathematics via a unique symbolic system. Spencer-Brown introduces a primary algebra based on…

So much has changed since I walked onto the Gaithersburg, Maryland, campus of the National Institute of Standards and Technology (NIST) almost three years ago to begin my term as its director and U.S. Commerce Undersecretary for Standards and Technology.  

We were all still…

Recent labor relations controversies and ongoing arguments about the minimum wage have raised questions as to how a supply chain should share the utility it produces.

If we ask the wrong question, however, we’ll get the wrong answer. “What is a fair share?” asks how a supply chain…

A recent Inc.com blog post by Jessica Stillman discusses Malcolm Gladwell’s new book, Revenge of the Tipping Point (Little, Brown and Co., 2024). The theme in both works is that you can’t create a high-performing team simply by bringing together individual high performers. They need to gel as a…

Gemini, O1, Grok, Claude, Llama, Yi, and Mistral: The number of large language models (LLMs) seems to have grown exponentially since OpenAI’s ChatGPT burst into the public consciousness in late 2022. It’s estimated that $154 billion was spent on AI by businesses in 2023, while the most recent …

Unplanned equipment downtime costs manufacturers an estimated $50 billion annually, according to a study by Deloitte. It is estimated that unplanned downtime costs more than $100,000 per hour. Traditional maintenance approaches—whether reactive or scheduled—are not sufficient to address these…

In manufacturing, especially in assembly systems, every operation plays a role in shaping the quality of the final product. The influence of these operations can carry through each stage, ultimately affecting the quality of the finished products delivered to customers. Understanding how these…

In today’s highly competitive global markets, lean manufacturing is no longer something that’s nice to have—it’s a way of life. You can either reduce costs, simplify operations, and improve productivity on a continual basis—or you can lose business to competitors that do.

Lean…

Generative AI is revolutionizing industries, from drafting legal contracts to crafting personalized marketing campaigns with unmatched speed and precision. Yet this transformative power comes with challenges: fears of job loss, concerns about algorithmic bias, and the phenomenon of “…

It’s 2024, and the age of automation has largely taken over our phones, computers, and businesses. This isn’t entirely a bad thing, you understand. It gives us the ability to spend time and money elsewhere—from investing in staff to spending more time on innovating technology rather than…

The ongoing relevance of the quality profession requires evolution and adaptation to meet the needs of the 21st century. Remember, the quality profession originated with the need for inspection to prevent poor quality from reaching customers; this was before it evolved to include metrology,…

Hexagon is frequently at the fore of innovation. Like many in its industry, part of the company’s initiative to succeed is rooted in the constant push to automate tedious processes that take up valuable time, eat up resources and personnel, and delay production and delivery of products. Tools…

It was another busy morning at the monthly operations meeting. Lindsay, the operations manager at TechElectronics, a growing manufacturer of consumer electronics, called the meeting to order. As usual, they started with the routine updates—inventory levels, production schedules, and customer…

Everyone has goals these days. The one that causes more disconnects than any other is a sales goal. It’s a number to hit (either units or dollars or both—the better ones are actually measured in profit dollars rather than revenue dollars). They’re problematic because by their very nature they…

A study by Upwork has revealed that about 22% of the American workforce will be working from home by 2025. Remote work is here to stay, bringing many benefits along with it—including significant cost savings for businesses and the promise of a better work-life balance for employees. However, the…

A quality management system (QMS) is at the heart of every successful medtech company. A QMS comprises all the policies, processes, and procedures that ensure the production of safe and effective medical devices—which means that problems with your QMS can quickly become problems with your…

The state of American manufacturing is in dire need of improvement. For decades, the U.S. economy has been transforming into a service-based model while the manufacturing power we associate with the American postwar capacity of the 1950s and ’60s has dispersed offshore.

This slow…

Welcome knowledge seeker! Do you feel dazzled and awed by the great potential of artificial intelligence (AI)? Perhaps hesitant or lost when terms like convolution, deep learning, or autoencoder are thrown around? Well, fear not, for you’ve come to just the right place. You don’t need to be a…

The goal: Using proven strategies, cut the clutter to focus on core priorities.

Nano Tools for Leaders—a collaboration between Wharton Executive Education and Wharton’s Center for Leadership and Change Management—are fast, effective tools that you can learn and start using in less…

In the ever-changing world of quality management, the intersection of innovation and standardization offers both exciting opportunities and tough challenges. Maria, a dedicated and certified quality professional, struggled with the concept of “standardizing innovation”—something that seemed like…

From small family-run companies to tech giants, the business world is changing at an unrelenting pace. Amid a constantly evolving economic landscape and sometimes dizzying technological advances, one thing remains constant: the need to maintain the highest level of quality.

…

Whether you’re a small machine shop or a large multimillion-dollar manufacturing giant, there’s no doubt you use dimensional gauges to maintain the standards for quality in your production.

The accuracy of these dimensional measuring instruments must be periodically checked to…

Limble CMMS has recently been recognized by Research.com, a reputable academic research platform, for its exceptional performance in the field of computerized maintenance management systems (CMMS). In its detailed review, Research.com names Limble as one of the top CMMS software solutions,…

We’re constantly seeking ways to both improve our business but save money at the same time. That can lead to the dangerous dynamic of “I’ll do it myself.”

Doing more with less can turn us into idiots. Our hubris and arrogance puts our idiocy into action. Sorry—I got a little ranty…

Thanksgiving dinner: the annual marathon of kitchen chaos, time crunches, and the occasional family squabble over cranberry sauce. For many, it’s the ultimate test of culinary coordination. But the truth is, organizing this feast has more in common with a modern production line than one might…

Construction is an asset-intensive industry. Companies depend on building equipment, power tools, construction vehicles, and all heavy machinery for essential functions like excavation, construction, and demolition. This equipment must always be kept in safe, proper, and optimal working order so…

Data breaches and cyberattacks are things that small to medium-size manufacturers think won’t happen to them. Yet, according to the Verizon 2023 Data Breach Investigations Report, 43% of all cyberattacks are conducted against small businesses.

If that doesn’t grab your attention,…

An engineer once told me, “I work on project teams that have an average half-life of two weeks, implementing solutions with an average half-life of two weeks.” Time after time, and in place after place, our improvement efforts often fall short of expectations and fade away. In this article, I…

Leadership is perilous territory. People’s lives are at stake (sometimes literally). Although avoiding the following seven deadly sins won’t guarantee you’ll be a great leader, succumbing to them will guarantee you’ll have a significant learning moment. (Translation: You’ll fail miserably, but…

In this article, I look at the idea of “sweeping-in” in systems approach. Sweeping-in can be described as the process of opening up the inquiry of a system by expanding its boundaries. Philosopher and systems scientist C. West Churchman discussed this process in several works, including Thought…

Speed is one of the most strategic elements a company can use to attract and retain customers and drive its revenues.

What do I mean when I talk about speed? In this context, speed means dramatically reducing the amount of time needed to complete a task by altering factors such as…

Facility and equipment maintenance is most effective when performed proactively and regularly. This kind of routine maintenance can take many forms, ranging from the most basic approaches to complicated strategies using sensors and data to trigger maintenance. Time-based maintenance (TBM) is a…

For an organization to develop a sustainable, continuous improvement culture, it must, as we say at Greater Boston Manufacturing Partnership, involve everybody, every day—i.e., process improvement must become an everyday part of everyone’s job. That’s the ideal.

The reality,…

It’s a story I’ve heard too many times: An organization spends years, even decades, entrenched in a top-down, command-and-control culture. In this environment, employees are micromanaged, decision-making is reserved for those at the top, and when things go wrong, the finger-pointing begins. “…

Everyone has their own favorite graph type or visual tool. I’m not ready to declare this my favorite yet, but this oldie but goodie has got to get more time and attention. That’s right: I’m talking about control charts with stages, also sometimes called before/after control charts.

We’ve already talked about what a strategic plan is (and isn’t) in our discussion: “Strategic Planning Isn’t ‘Budget +10%.’” Hopefully, you’ve now got a direction mapped out and a list of initiatives to pursue, and you’re ready for a little tactical strategic advice. (Yes, that phrase is…

A few days after returning from a speaking engagement at the Innovate for Excellence Summit in Chicago last September, I spoke to Susan, an old classmate. We chatted for a while, and naturally the conversation drifted toward innovation—something we’re both passionate about. She asked me about my…

If you’re reading this, you probably read a lot. You’ve made your way through all our industry news, keeping tabs on trends in our feature stories and gleaning a greater understanding of your own business—at least we hope so.

And if you read this much, it may be that you do a fair…

How do you treat signs when you’re driving your car? Are you a strict rule follower? Does a stop sign cause you to come to a full stop, or a rolling stop, or no stop at all if you see no traffic? What about that intersection you go through every day, where you never see a car approaching from…

W ithin the utility industry, regional entities increasingly focus on internal controls as a measuring stick for overall compliance performance.

Developing and executing rock-solid internal controls with an automated compliance management software solution can help maintain…

Despite the industry’s push toward digital transformation, 95% of manufacturers use paper-based documentation, according to Forbes. But modernization doesn’t have to be overwhelming for manufacturing teams.

When implemented strategically, digital documentation can improve…

In this article, I’m looking at Weber’s Law. It’s named after Ernst Heinrich Weber (1795–1878), a German physician who was one of the pioneers of experimental psychology. I highly recommend the Numberphile YouTube video that explains this in detail.

A simple explanation of Weber’s…

Despite the clear benefits of hybrid work models, a significant number of managers still push for their teams to be back in the office. A KPMG report of responses from 100 CEOs of large companies shows that more than a third expect to have all corporate workers back to the office full time by…

Not long ago, I accompanied two of the Greater Boston Manufacturing Partnership’s consultants, Bob Elliott and Peter Melnik, to a Shingo Systems Design workshop at Osram, a terrific host site in Hillsboro, New Hampshire. Bob and Peter did all the work. My job, in the spirit of continuous…

All improvement efforts require a framework. No matter what we’re doing, we all need some way to align our efforts and focus on a specific objective. During my 50 years in this business, I’ve seen people use many different improvement frameworks. Most of these have been variations on either PDSA…

This ain’t your daddy’s or mommy’s business world anymore. I’m sure you’ve figured that out already. First of all, people use cell phones. I keep reminding my father.

“Dad, turn on your cell phone when you’re not home.”

“Why? Then it will ring. I’m retired, and I don’t want…

The Associated Press, reporting on the strike by the International Longshoremen’s Association, noted, “Local ILA president Boise Butler said workers want a fair contract that doesn’t allow automation of their jobs.” The report added, “The union had message boards on the side of a truck reading…

More and more companies in the manufacturing industry admit that providing great customer experience is vital to their business success. 41% of respondents to the “2024 State of Manufacturing Report” by Fictiv consider enhancing customer experience (CX) one of their top three priorities for this…

Asset maintenance isn’t just about fixing things when they break. It’s a complex mix of strategies, both proactive and reactive. Finding the most cost-effective blend makes all the difference in the success of your maintenance program and your business as a whole.

Whether your…

In modern manufacturing practices, it’s vital to be able to cut costs and time without cutting corners. Enter an increasing reliance on AI tools to generate automated and accurate documentation, predict outcomes, and increase the reliability and accuracy of data. Within this realm, Infor is one…

‘The secret of my success is that we have gone to exceptional lengths to hire the best people in the world.”

That quote of Steve Jobs, founder of Apple, underscores the importance of putting together a team of people who will drive your business to heights you would never believe…

Amazon’s recent decision to require corporate employees to return to the office five days a week is generating significant controversy. In a memo to employees, CEO Andy Jassy emphasized the benefits of in-person work, such as increased collaboration, innovation, and cultural connection.

Asset management is an integral part of a smoothly running business. It facilitates accurate forecasts, prevents theft and loss, and optimizes resources. However, according to the Wasp Barcode State of Small Business Report, 55% of small businesses still use manual asset management or don’t…

Metal cold-rolling is a critical process in manufacturing various steel and aluminum products. As manufacturers look for ways to modernize and streamline their manufacturing and quality control processes, digital technologies are poised to transform the metal cold-rolling industry by offering…

There’s perhaps no better reputation for quality than Stradivarius. As I’ve learned from Wikipedia, a Stradivarius is a violin or other stringed instrument “built by members of the Italian family Stradivari, particularly Antonio Stradivari (Latin: Antonius Stradivarius), during the 17th and 18th…

I once attended a presentation that Eli Goldratt gave for the Society of Manufacturing Engineers. We were seated in an auditorium, listening as Goldratt paced back and forth on the stage, puffing on his cigar, gesturing for effect, and occasionally cursing for emphasis. The author of The Goal (…

In the near future, significant and unpredictable external factors may combine to challenge the global business landscape in unprecedented ways. Responding effectively to those challenges will require adaptability. Although many leaders acknowledge its importance, even successful companies can…

ResumeBuilder.com, a premier resource for professional resume templates and career advice, has published a recent survey report assessing companies’ return-to-office (RTO) plans. The report also provides insights into the motivations behind these findings.

The survey reveals that…

When you think of good customer service—particularly the barriers to it—two factors generally come to mind: timing and wording. Imagine walking into a store that sells soap and bodywash products and immediately being bombarded with, “May I help you?” “Looking for anything today?” or the dreaded…

Most quality practitioners are familiar with the Taguchi loss function, which contends that the cost of any deviation from the nominal follows a quadratic model. This is in contrast to the traditional goalpost model, where anything inside the specification limits is good, and anything outside…

Many people don’t realize just how long AI has been around in the healthcare industry—and are surprised to find out that it’s something that’s been relied on for 50 years already.

MYCIN, a computer-based model with machine learning capabilities, was developed by a team of…

The objective of all improvement projects should be to improve the overall process. Everything else should be secondary to this objective. If you improve the efficiency of a support process, or even a portion of the core process, but at the same time lower the efficiency of the overall process,…

As a leadership keynote speaker, I’ve encountered countless professionals struggling with procrastination. We’ve all been there–staring at a mountain of “should-do” tasks while our minds wander to more enticing activities. But what if I told you there’s a way to turn those dreaded tasks into…

In the world of continuous improvement and lean management, clear and respectful communication is crucial.

Let’s take a moment to examine two different approaches to communicating a simple instruction regarding the operation of a centrifuge, as seen in the images below—pictures I…

In the complex, uncertain, and fast-changing world we live in, success and even survival require intensive collaboration among individuals, organizations, and countries. The outcomes of such collaboration can be breathtaking: Consider the growth of Netflix and Amazon, the rebirth of Microsoft…

Whether you’re an executive with limited energy or an hourly employee trying to minimize work, the bottleneck in your productivity isn’t time or money but mental effort. And in a digital age where all data can be stored electronically, the most valuable functions of software—especially those in…

The “comfort zone” is that cozy space where everything feels familiar and stress-free. It’s where we stick to what we know, using the same old strategies that keep things steady but can also lead to feeling stuck.

In this zone, there’s not much motivation to push for new…

‘T ake out the papers and the trash.” That was the opening line of the song “Yakety Yak” by The Coasters. It spent weeks as the No. 1 hit in 1958. Teenagers everywhere wore out their shoes dancing to the hot song. The lyrics hold a strong message about delivering a superior customer experience…

Traditional productivity metrics are used by many companies to assess the value that employees bring to the organization. These tangible, quantifiable, results-based measurements include work quality and output, efficiency, and the number of projects completed on time and on budget. Some…

At a time when virtual meetings, video conferences, and online work calls are the norm, there’s good news for those who see a unique value in in-person networking. A survey conducted by Harvard Business Review has found that 95% of professionals believe face-to-face meetings are crucial to…

In a previous article, I discussed the concept of “stress bragging”—that tendency to boast about our stress levels as a way to highlight our productivity and importance. I touched on ways to curb this habit in ourselves. But what about when others do it? Here are some effective strategies for…

The four common capability and performance indexes collectively contain all of the summary information about process predictability, process conformity, and process aim that can be expressed numerically. As a result, any additional capability measures that your software may provide can only…

I have always been interested in the idea of autonomy in a social setting. In this article, I’m looking at autonomy in a social setting—such as an organization—from a cybernetics viewpoint. I’ll lean on the ideas of Heinz von Foerster and Stafford Beer.

Von Foerster came up with…

I love gardening and growing fresh vegetables. Recently I had checked in on my Brussels sprouts seedlings and, well, they looked awful! The reason quickly became obvious to me: I had overwatered them.

I was so excited about growing Brussels sprouts this year, I didn’t want…

When a foreign company wants to manufacture goods in the United States, it needs new domestic suppliers for just about everything. When such an initiative involves new technology, it creates even more opportunities for a regional ecosystem and associated supply chains.

Topsoe is a…

As years roll on, I’m noticing more parts of me breaking down: Teeth, eyes, knees, cardiovascular, stomach—the list keeps getting longer, as does the list of docs I see. I’m blessed to be living in an area with the world’s finest medical care and lucky that healthcare innovation (and Medicare)…

Look through even a few FDA warning letters and you’re likely to find violations related to change management.

For instance, a recent warning letter from the U.S. Food and Drug Administration cited a pharmaceutical manager for changing drug components without justification.…

The plan-do-check-act (PDCA) cycle plays a central role in fostering improvement by facilitating a structured and ongoing approach to problem-solving. Because the PDCA cycle is ongoing, it also plays a central role in helping organizations navigate shifts in the economic climate, align with new…

QIMA, previously called AsiaInspection, is known for not only making inspection and certifications easier, but also increasing accessibility via a convenient digital platform and strong focus on compliance. Both SMEs and e-commerce businesses have benefited from this increase in affordability…

I’ve seen a rash of articles about major league baseball pitchers who are now out for the season because they’ve hurt their elbow and need “Tommy John” surgery. This includes some big names, such as 2020 Cy Young Award winner Shane Bieber of the Cleveland Guardians.

My favorite…

As the modern work environment continues its march toward remote settings, managers are increasingly turning to agile metrics to keep their teams trackable and transparent. But what’s all the fuss about? Why are these tools not just beneficial but essential?

In this article, I’m looking at the relationship between capability index (Cpk or Ppk) and tolerance intervals. The capability index is tied to the specification limits, and tying this to the tolerance interval enables us to use the confidence/reliability statement allowed by the tolerance…

One hundred years ago this month, Walter Shewhart wrote a memo that contained the first process behavior chart. In recognition of this centennial, this column reviews four different applications of the techniques that grew out of that memo.

The first principle for interpreting…

Across the country, hundreds of thousands of drivers deliver packages and parcels to customers and companies each day, with many click-to-door times averaging only a few days. Coordinating a supply chain feat of this magnitude in a predictable and timely way is a longstanding problem of…

Deming Prize recipient Ryuji Fukuda introduced a document to my company in 1989 referred to as the “X-Type Matrix for Objective Management.” Relatively unknown at the time, it’s since become a popular format for strategy deployment.

Named for the X format that connects strategic (…

This article is an excerpt from the cutting room floor. It was in an early draft of my book One Piece of Paper: The Simple Approach to Powerful, Personal Leadership (Jossey-Bass, 2011; order your copy here). It covers how to lead through guidelines rather than leading through rules.

…

I was asked to lead a workshop in the sales order department of a manufacturer that we had helped with process improvement on the factory floor. Those efforts had positively reverberated across the company in the form of fewer late and expedited orders. Still, sales order employees were…

Amid seemingly never-ending layoffs and a laser focus on efficiency, companies expect their employees to make productive and focused use of their time on the clock. Yet, research has shown that they often spend a significant amount of time cyberloafing—using the internet for personal purposes…

Sometimes the key to getting a lot done is to actually do nothing at all.

I’ve been dreading writing this post. Massive writer’s block. “I have nothing to say,” says the tired little voice in my head (no comments from the peanut gallery).

Normally, I write on Sundays.…

Pay. It’s the topic we love to avoid. We don’t discuss it with friends or family. It’s verboten at cocktail parties. Heck, we discuss cancer, religion, and abortion at dinner parties more easily than we talk about our paychecks. We don’t even like to discuss compensation with the person whose…

In less than two months we will celebrate the 100th anniversary of the invention of the control chart, a tool most often associated with statistical process control (SPC). Considering SPC from our modern perspective made us ask, “Is SPC still relevant?”

It’s a question asked…

Companies today implementing automated compliance management systems are motivated by a wide variety of factors.

For many, it’s about reducing manual labor hours required to execute quality processes—and achieving greater efficiency and effectiveness in their operations. For…

When presented with a collection of data from operations or production, many will start their analysis by computing descriptive statistics and fitting a probability model to the data. But before you do this, there’s an easy test that you need to perform.

This test will quantify…

Medical equipment is a necessary yet substantial investment for any health system. Making strategic decisions about these assets can be daunting in the face of shifting patient demand,  financial uncertainty, and fast-changing cybersecurity risks. 

Because clinical assets account…

In a humorous moment from Steve Martin’s comedy Father of the Bride, there’s a scene where George Banks (Martin) argues with a store clerk that the number of buns in a package is mismatched with the packaged number of hot dogs: “I wanna buy eight hot dogs and eight hot dog buns to go with them.…

The cost of poor quality can be devastating to business: Failed quality control costs manufacturers anywhere between 15–20% of their total profits on average, and as much as 40% for some, the ASQ reveals. Businesses with successful quality programs, on the other hand, can benefit from increased…

Have a massive, daring goal in mind? Breaking it into smaller steps can help you achieve your dreams.

A research paper led by Wharton Ph.D. alumni Aneesh Rai and Edward Chang and co-authored by Wharton professors Marissa Sharif, Katy Milkman, and Angela Duckworth found that…

Implementing an automated compliance management solution is a mammoth undertaking with high stakes and potentially high returns for those who navigate the process successfully.

Get it right and you could save thousands of labor hours, avoid millions of dollars in compliance issues…

I’ve learned so much from Timothy R. Clark of the firm LeaderFactor, and author of the excellent book, The 4 Stages of Psychological Safety (Berrett-Koehler, 2020). I can’t recommend his work enough—including his free podcasts, webinars, and more. I was fortunate to go through a formal…

If you ever feel like some parts of your work turbocharge your day while other parts leave you running on empty, it might be time for an energy audit.

This exercise can be a game-changer if you feel unmotivated or uninspired by your work. Here’s how to do it.

Reflect on…

In his Quality Digest article published in February 2023, Michael Mills1 reported that the next version of ISO 9001 will add to clause 4.1, “Understanding the organization and its context” the words, “the organization shall determine whether climate change is a relevant issue.”

…

Tracking work orders is an essential aspect of work order management, and it becomes immensely more efficient with the help of tracking software.

Work orders are the centerpiece of an effective maintenance program. Once a work order request is initiated, it triggers a set of tasks…

Emails that drone on and on. Meetings that could have been Slack messages. Memos loaded with empty jargon. We’re all familiar with friction, or what Robert I. Sutton and Huggy Rao describe as “forces that make it harder, slower, more complicated, or downright impossible to get things done.”…

Global trends and data-driven development in different industries dictate the need for permanent change and finding ways to be more effective for stakeholders and project participants. This is reflected in many types of business through new technologies, new collaboration processes, new org…

Over the past two months we’ve considered the properties of lognormal and gamma probability models. Both of these families contain the normal distribution as a limit. To complete our survey of widely used probability models, this column will look at Weibull distributions, a family that doesn’t…

Generative AI took the world by storm in 2023, from the classroom to the film studio, and the writer’s bench to the White House. Enterprises and creative industries worked to figure out how to leverage it in their operations, while classrooms and government entities struggled to govern its use…

In manufacturing industries, calculating overall equipment effectiveness (OEE) offers deep insights into the performance of production processes and enables data-driven improvements. 

Determining OEE is a standard method for assessing the productivity of production lines compared to…

Continuing on the theme of value stream mapping (and process mapping in general) from my article “Where is your value stream map?”, I outlined the typical scenario: The map is built by the continuous improvement team, and they are the ones primarily engaged in the conversations about how to…

Utility companies play an essential role in our communities, supporting our well-being and quality of life. But providing always-on services that rely heavily on machinery, technology, and other assets can pose a challenge. In the dynamic and demanding world of utilities, mastering the art of…

Just two months after its launch in late 2022, ChatGPT reached 100 million monthly active users. Along with other advanced language models, it quickly began encroaching on territory traditionally exempt from automation, such as tasks requiring creativity, intuition, and decision-making.

…

By now you will have already broken one or more of your resolutions for the new year. You didn’t mean to; it was just so hard to keep that major commitment. While I do believe in setting worthwhile and measurable goals for a new year, I prefer identifying small changes I can sustain throughout…

The term lean maintenance describes a methodology that focuses on eliminating waste and continually identifying opportunities for improvement. Over time, a lean approach to maintenance extends the useful life of assets, maximizes profitability, improves resource allocation, and enables more…

Quality consistently ranks among organizations’ foremost competitive priorities; it’s a prerequisite for success in the global marketplace. Firms that want a competitive edge do it by delivering products that meet customer needs and function as intended.

Despite the long-standing…

By eliminating low-value work from your life, you can focus on more important things. Get rid of difficult customers and focus on driving your business instead.

To get your new year started right, I’d like to share with you what I’ve been taught by homemade bread, lawn mowers, and cheap…

Let me introduce the five “Al” siblings: informational, aspirational, foundational, directional, and decisional. Also, meet their young cousin, survival.

In my years of learning about organizations and teaching graduate students about strategy and organizational analysis, I have seen…

When do we need to fit a lognormal distribution to our skewed histograms? This article considers the basic properties of the lognormal family of distributions and reveals some interesting and time-saving characteristics that are useful when analyzing data.

As we launch into Industry 4.0, the need for advanced automation and high-performance connectivity solutions intensifies, requiring protocols like Industrial Ethernet for maximum efficiency and productivity. Products like ix Industrial and Single Pair Ethernet are ideal new interconnects,…

You are assigned a new task to demonstrate that an existing process will have the capability to meet newer and tighter specifications. The change in specifications for critical-to-quality characteristic P is due to new regulatory requirements; hence, the specifications must be met. The task is…

In the ever-evolving landscape of manufacturing, operational efficiency is paramount. The seamless functioning of machinery not only ensures optimal production but also minimizes downtime and associated costs. However, for a certain manufacturing company that had been operating in a reactive…

Environmental consciousness is a priority for both consumers and businesses, now more than ever. Sustainable business practices continue to gain popularity across various industries, including the nutrition and food industry. In this realm, scientific laboratories are a resource-intensive space…

One large concern when maintaining a business’ facilities and assets is cost. Managing the costs of repairs, new parts, and personnel can present a challenge.

Although maintenance can be costly, it’s important to see it as an investment that prolongs equipment life span, enhances…

At one point in my career, after managing design controls and risk management documentation, I decided to move on.

When the day came to put in my two-week notice, I walked over to another engineer’s cubicle with the news. “From now on,” I said, “design controls are yours.”

I’ll…

As the growth in fulfillment warehouses, e-commerce, and third-party logistics skyrockets, and unique customer demands evolve, more companies are exploring the concept of dark warehouses—fully automated, “lights-out” facilities that use intelligent, interconnected devices to operate without…

Historically, manufacturing processes have often involved substantial waste. From the early days of industrialization, companies have prioritized production speed and volume over efficient resource use. As resources seemed abundant and environmental consciousness was low, excessive waste became…

Nano Tools for Leaders—a collaboration between Wharton Executive Education and Wharton’s Center for Leadership and Change Management—are fast, effective tools that you can learn and start using in less than 15 minutes, with the potential to significantly improve your success.

…

We are one year away from the 100th anniversary of the creation of the control chart: Walter Shewhart created the control chart in 1924 as an aid to Western Electric’s manufacturing operations. Since it’s almost prehistoric, is it now time to leave the control chart technique—that started out…

Today’s manufacturing systems have become more automated, data-driven, and sophisticated than ever before. Visit any modern shop floor and you’ll find a plethora of IT systems, HMIs, PLC data streams, machine controllers, engineering support, and other digital initiatives, all vying to improve…

Over the past decade, one of the biggest advances in enterprise resource planning (ERP) has been the ability to communicate and integrate with machines and external software programs to lower costs and increase efficiency. For example, BOM Compare software can reduce engineering costs and get…

Imagine a manufacturing world where machines seamlessly collaborate with artificial intelligence (AI) to ensure flawless quality inspection. It’s a future that holds immense potential for revolutionizing the industry.

Major manufacturers like FANUC, ABB, and KUKA AG, alongside…

Today I’m looking at some practical suggestions for reducing sample sizes for attribute testing. A sample is chosen to represent a population. The sample size should be sufficient to represent the population parameters such as mean and standard deviation. Here we’re looking at attribute testing…

You’re in an early-stage hardware startup or a tinkerer in a toolshed with a product design set to shake up the market. Not sure how to turn your idea into a product? Here’s a step-by-step guide to the product development journey. From the initial design sketched out on paper to the final…

I’ll admit it: After five decades watching U.S. companies turning to simplistic accounting tricks to remain profitable, I’m discouraged.

I was a kid when I first discovered the Toyota Production System (TPS). My eyes were opened to the immense amount of waste in our production and…

The difference between common (or random) cause and special (or assignable) cause variation is the foundation of statistical process control (SPC). An SPC chart prevents tampering or overadjustment by assuming that the process is in control, i.e., special or assignable causes are absent unless a…

Meetings give me a rash. A really bad one. One that not even calamine lotion can soothe. The only things worse than meetings are reports. Standard daily reports, weekly reports, hourly reports. Reports on the status of reports. If I wasn’t already insane, these things would drive me insane.…

If you could experience the perfect workday, what would you be doing? Have you ever taken the time to think about it? 

Whether you’re an entrepreneur climbing the corporate ladder or you’re selling donuts out of the back of your car, it’s essential to pause and reflect periodically on…

As we learned last month, the precision to tolerance ratio is a trigonometric function multiplied by a scalar constant. This means that it should never be interpreted as a proportion or percentage. Yet the simple P/T ratio is being used, and misunderstood, all over the world. So how can we…

Let’s start with a definition of Industry 4.0, keeping in mind that we’re rapidly approaching Industry 5.0. Industry 4.0 is an era marked by enhanced digitization and the increased connectivity of smart technologies. Where Industry 5.0 is more values-driven, it will require the technology of…

An increasing number of engineers are embracing design for manufacturing (DFM) to streamline their production workflow. Industry leaders such as Apple, GE, and Samsung have already adopted DFM as part of their standard practices. If you’re using the “over the wall” engineering strategy—one where…

The success run theorem is one of the most common statistical rationales for sample sizes used for attribute data.

It goes in the form of:

Having zero failures out of 22 samples, we can be 90% confident that the process is at least 90% reliable (or at least 90% of the population…

Mental toughness is a quality that sets extraordinary individuals apart from the rest, enabling them to endure discomfort and uncertainty for extended periods. But what exactly is mental toughness? Can it be achieved without undergoing severe stress and trauma? Why do some people seem to possess…

Peter Drucker, celebrated by BusinessWeek magazine in 2005 as “the man who invented management,” is credited with a concept that has created confusion for me throughout my work life: the distinction between knowledge work and manual work.

In his 1959 book The Landmarks of Tomorrow (…

Risk analytics is a vital component of risk management that uses statistical models, data analysis, and predictive modeling techniques to assess, quantify, and mitigate risks in various domains. This article will delve into the definition of risk analytics, discuss its importance, and explore…

Creating a well-run facility isn’t as simple as it appears. It requires meticulous planning, dedicated resources, and a keen eye for detail to ensure that all elements, from the largest machines to the smallest fixtures, function as intended.

All these aspects fall under the umbrella…

One of the things I hear from many people is they want to improve their ability to focus. If they just had a distraction-free environment, they could get the right things done. Well, I’m writing this from a distraction-free environment—one of those booths they have at airports where you can make…

Nano Tools for Leaders—a collaboration between Wharton Executive Education and Wharton’s Center for Leadership and Change Management—are fast, effective tools that you can learn and start using in less than 15 minutes, with the potential to significantly affect your success.

…

Last May marked the 35th anniversary of the Shingo Prize, an award bestowed each year to recognize organizations that demonstrate the principles and methods espoused by its namesake, Shigeo Shingo. Although I haven’t made it to every celebration and award ceremony, it turns out that I was the…

A new study from the University of Birmingham has found that managers have developed a more positive outlook on the benefits of hybrid work productivity since the Covid-19 pandemic. The research surveyed 597 managers and found that 51.8% of them agreed that working from home improves employee…

Time value of money calculations, including net present value analysis, is important when selecting projects and investments. The calculations are part of the body of knowledge for some of ASQ’s certification exams. They also go a long way toward explaining exactly what happened to Silicon…

It’s increasingly common for today’s warehouse managers to pursue robotic material-handling solutions. That approach can boost productivity, reduce injury rates, and enable companies to adjust to changing demands. However, before company decision-makers choose what kind of robots they want, they…

The ability to observe relationships, patterns, and environment may be deemed a “soft” skill, but there’s plenty of hard data supporting the power of observation in the workplace. After all, observation is the sometimes overlooked first step in the scientific method: Make an observation, and…

Unpredictable schedules are so disruptive to the lives of employees that even 30 days of high shift variability in a year increases the chances a worker will quit by 20 percent, according to a new study from Wharton experts. Employers use just-in-time scheduling to cover peak demand and raise…

I’m looking at ideas of the famous Algerian-French philosopher, Jacques Derrida, often described as a post-structuralist. His most famous idea is deconstruction, often associated with analyzing literary works. A text is presented as a coherent whole with a basic idea in the center. The text’s…

It’s no secret that there are no universally applicable organization designs. What works in one context may not work in another because each organization has a different history, culture, and cast of characters. And yet there is a thriving segment of the management consulting business that…

I’m ashamed to say that I’ve only been to Indiana once—for a fun weekend in Indianapolis. I will say that its Children’s Museum is truly world-class, and it was great going duckpin bowling for the first time.

Though I haven’t taken full advantage of Indiana as a tourist destination (yet…

“The best is the enemy of good,” wrote French historian and philosopher Voltaire. Today that quote seems more appropriate than ever. A longitudinal meta-analysis study from 1989 to 2016 looking at data from more than 41,000 students across the U.S., U.K., and Canada revealed that perfectionism…

There’s a certain irony in the recent attention paid to the application of robots on the shop floor. On a couple occasions in the past year, I’ve heard manufacturing colleagues talk about the benefits of deploying robots to handle material conveyance. “Better,” they say, “to redeploy humans to…

Producing high-quality products is crucial for any business. But designing quality into the product from the start is the only significant way a business can improve its product margins. When you use detection methods and find a nonconformance, you’ve already invested in that nonconforming…

Continuing our thinking about ways for data leaders to save money during a recession, this article drills into saving on your data usage. Following my last post reminiscing on the lessons I learned during past recessions, the early environmentalist slogan “reduce, reuse, recycle” has stayed in…

A major focus of the current administration is revitalizing American manufacturing as new technologies are changing the way things are made. Manufacturing Extension Partnership (MEP) director Pravina Raghavan recently appeared on Government Matters TV, where she discussed how MEP National…

When it comes to maintaining the critical infrastructure and machinery of your facility, choosing the right maintenance contractor can make all the difference. It's essential to find a contractor who not only has the knowledge and skills to keep a maintenance program running smoothly, but also…

The business challenges of the past few years—labor shortages, supply chain disruptions, and inflation—have accelerated the long-term trend toward automated packaging operations.  All types of manufacturers and distributors, including food and beverage, pharmaceuticals, automotive, and e-…

It’s old news, but since 2019 the U.S. now has three times its former number of remote workers. Furthermore, an astounding 97.6 percent of employees want that option to remain at least partially on the table for the remainder of their careers.

But how compatible is this with the American…

There is more to lean manufacturing than improving a few processes. Sustainable lean success requires a companywide culture of continuous daily improvement. Companies that develop their people to think scientifically, using facts and data to drive their decisions, are often the ones that most…

Collaboration has become an important feature of various industries, particularly when it comes to creative work. This comes amid growing interest in nonhierarchical structures with autonomous teams and the increasing prevalence of open innovation.

The benefits of collaboration—be it…

The U.S. utility industry, a cornerstone of modern infrastructure, is undergoing a significant transformation. Recent trends, primarily the shift toward renewable energy, are reflected in the sector’s changing statistics. 

Strategic asset management in the utility sector is essential for…

The manufacturing industry (largely) welcomed artificial intelligence with open arms. Less of the dull, dirty, and dangerous? Say no more. Planning for mechanical assemblies still requires more than scratching out some sketches, of course—it’s a complex conundrum that means dealing with…

Research shows that during times of economic uncertainty, companies that find a balance between reducing the resources they need to survive and investing in key areas for growth will fare better through a recession and beyond. It’s a nuanced approach that involves playing offense and defense at…

Manufacturers spend too much on quality issues. Some issues they are blind to, some are due to poor detection, and some are the costs incurred when issues escape to a customer.

It seems like in recent years the challenges have been great in both magnitude and quantity—supply chain…

The very nature of healthcare construction and its specific infrastructural and functional needs pose significant challenges to the architectural, engineering, and construction (AEC) sector. Crucial hospital spaces such as operation theaters and critical care centers need fail-proof connections…

Corrective action and preventive action (CAPA) is probably the most important process in any quality management system because so much else depends on it. This includes not only its traditional role as a response to defects, nonconformances, customer complaints, and audit findings, but also…

Founded in 2012, GoFormz is a uniquely flexible documentation platform for professionals in all industries—and a long-awaited solution for those chasing lean efficiency without sacrificing quality.

What does that mean? Well, unlike using a fillable PDF or Adobe document, GoFormz is an…

Corrective and preventive action (CAPA) is a core function in any quality management system (QMS), and a critical piece in the plan-do-check-act process approach. Like any quality process, tracking CAPA key performance indicators (KPIs) is crucial to continuous improvement.

It’s also a…

Soft skills, the behavioral and social traits that enable individuals to work harmoniously with one another, aren’t just nice to have. They’re essential for the growth of a nation.

In France, 60 percent of employers consider soft skills, such as the ability to organize, adapt, and work…

In recent years, pretty much every assumption about how, where, and when we work has been upended. But I believe we’re still at just the beginning of a revolution in hybrid work.

Today, there’s a clear opportunity for organizations to step into the next wave of working, supported by even…

Once again I’m going through old files. Looking back at my notes from 2005, I believe I was thinking about nailing these points to a church door somewhere in the company. That actually isn’t a bad analogy because I was advocating a pretty dramatic shift in the role of the kaizen workshop leaders…

Even before the pandemic, burnout was labeled as an epidemic. It’s the persistent work-related stress that’s exhausting and impairing. In the U.S., more than half of employees feel burned out at least some of the time, and it can lead to what has recently been termed “quiet quitting”—reduced…

AStanford Medicine-led study has found that borrowing certain billing- and insurance-related procedures from other countries could lead to policies that drastically lower healthcare costs in the U.S.

The new study, published in the August edition of Health Affairs, compares costs of…

Water is the most essential resource for life, for both humans and the crops we consume. Around the world, agriculture accounts for 70 percent of all freshwater use.

I study computers and information technology in the Purdue Polytechnic Institute, and direct Purdue’s Environmental…

Many manufacturers that adopted lean principles by applying a “just-in-time” (JIT) mindset to inventory of materials and parts have been burned, sometimes badly, by cascading supply chain disruptions. Broken links in the supply chain have created havoc, especially for smaller manufacturers.…

Over two days, engage in eight unique best practice sessions with 11 process improvement and thought leaders at S.O.A.R. 2022, OpusWorks’ annual virtual conference.

Designed to present highly actionable information and game-changing strategies from highly experienced and inspiring human…

In today’s column, I’m looking at the Ohno Circle in light of German philosopher Martin Heidegger’s ideas. I’ll try to stay away from the neologisms used by Heidegger and will only scratch the surface of his deep insights.

One of the best explanations of the Ohno Circle comes from one of…

In industry, gas-fired boilers have been the standard for decades to produce steam and heat process water. However, not all boilers are created equal in terms of safety. By definition, combustion-fueled boilers can emit harmful vapors, leak gas, and even cause explosions and fires.

In a…

Virtually all wind turbines, which produce more than 5 percent of the world’s electricity, are controlled as if they were individual, freestanding units. In fact, the vast majority are part of larger wind farm installations involving dozens or even hundreds of turbines whose wakes can affect…

Industry 4.0 has been a hot topic for years now, for good reason: 86 percent of manufacturing C-suites say digital transformation is a priority, and about 91 percent of industrial companies are investing in digital factories. Yet Industry 4.0 has also become a buzzword in many ways, as so many…

With GBMP’s 18th annual Northeast Lean Conference on the horizon, I’m reflecting on our theme, “Amplifying Lean—The Collaboration Effect.” The term collaboration typically connotes an organized attempt by unrelated, even competitive, parties to work together on a common problem; for example, the…

Food processors have long sought a safer, more energy-efficient means to convey product with less spillage, breakage, or downtime due to necessary cleaning and maintenance. Although tubular drag conveyors have offered these desired attributes compared to belt, bucket, or pneumatic systems, many…

You may not be familiar with the term “information technology asset management” (ITAM), but most businesses deal with it on a regular basis (for better or worse). ITAM is what helps control the costs of computers, servers, software, and services used to create the computing environment modern…

The conditions that led to a shortage of baby formula were set in motion long before the February 2022 closure of the Similac factory tipped the U.S. into a crisis.

Retailers nationwide reported supplies of baby formula were out of stock at a rate of 43 percent during the week ended May 8…

The pandemic had many consequences for manufacturing companies, the most prevalent being supply chain disruption. In light of these disruptions, it is paramount that organizations establish robust and reliable operations to ensure productivity targets are met—especially as consumer demands…

Manufacturers work hard to minimize disruptions to their operations and invest significant resources to minimize production risk. They also are under constant pressure to find new ways to deliver more value to their customers. Sustainable business growth is critical to delivering this value.…

There’s no better time than now. As a species, we need to mitigate the effect we have on our planet. There are many ways to do this—namely, through green and eco-friendly initiatives—but one sector is having the biggest impact of all: the industrial and manufacturing sector. In the 2010s, the…

Negotiating a salary increase or a job promotion ranks high on the list of hard conversations to have at work, and it doesn’t get any easier without a plan.

“People think, ‘I’m just going to knock on their door, sit down with them, and noodle around and see where this goes.’ That’s not a…

Ryan Day1 describes how the rise of independent auto dealers is a “gray swan” event for the automobile industry. This was not only bound to happen, as observed by the author, but also long overdue. The article states, “...current state laws prohibit OEMs from selling new vehicles directly to…

As the world moves toward a new, post-pandemic normal, industries must leverage digital transformation at an accelerated pace. This is already happening. According to IBM, 67 percent of manufacturers have accelerated digital projects since Covid-19.

Although improved operational…

Every February, there are welcome reminders that spring is on the way. The first for me is a witch hazel bush in my front yard that defies subfreezing weather to produce fragrant yellow flowers. Then, a few weeks later, crocuses and winter aconites will emerge from the snow. The cycle continues…

The lean manufacturing movement evolved from a desire to reduce waste and inefficiencies and improve productivity on the shop floor. Many manufacturers have also benefited from the resulting continuous improvement mindset as engaged employees became empowered to change things for the better.…

Kendrick Plastics is an IATF/TS 16949-certified, tier one and tier two supplier of interior decorative trim components and assemblies to the automotive industry. Located in Grand Rapids, Michigan, its 300,000 sq ft engineering and manufacturing facility has more than 50 presses serving fully…

This isn’t a new story: A novel technology disrupts society, bringing with it many benefits but also major risks and costs. We saw it during the Industrial Revolution, which vastly improved the average living standard but also led to poor labor conditions and environmental degradation, all…

Welding technology has progressed over the years, thanks to innovations that improve accuracy and overall productivity. Some advances have been in welding automation handled by advanced robots. Other breakthroughs rely on artificial intelligence (AI) and machine vision for better defect…

I’m a chemical engineer. The fundamentals of the chemical engineering profession were laid down 150 years ago by Osborne Reynolds. Although chemical engineering has seen many advances, such as digital process control and evolutionary process optimization, every engineer understands and uses…

Communities across the U.S. Southeast and Midwest are assessing damage from the deadly and widespread tornado outbreak on Dec. 10–11, 2021. It’s clear that the cleanups will take months and possibly years.

Dealing with enormous quantities of debris and waste materials is one of the most…

In 1996, the TSSC (Toyota Production System Support Center) began working with my company to create one-by-one production capability in our product assembly. Previous to TSSC’s assistance, we’d moved the furniture and machines into cells, creating the appearance of flow production, but we lacked…

With the holidays fast approaching, manufacturers, distribution centers, and e-commerce providers are working to meet growing customer demand, while also navigating severe supply-chain disruptions and mounting labor shortages. At this point, we all had hoped to have the devastating effects of…

Within every organization, problems or incidents arise that can affect the quality of your operations. Take for example, food recalls due to improper food labeling that not only could cause sickness in humans, but also result in a hit to a company’s reputation. Or, automotive product recalls due…

Manufacturers should routinely ask themselves: “How do I know what my problems are?” The old-school way to answer this question was based on having the resources to produce spreadsheets of operational data and the expertise to analyze the data and understand how to respond.

This…

This article contends that we should replace “quality” with “value” to address an enormous array of previously unaddressed risks and opportunities. Poor quality is only one of the Toyota Production System’s seven wastes, and it is rarely the most costly one because it is also the only waste to…

Ningbo-Zhousan may not exactly be a household name, but find something in your house made in China, and it’s quite likely it was delivered from there. Ningbo-Zhousan, which overlooks the East China Sea some 200 km south of Shanghai, is China’s second-busiest port, handling the equivalent of some…

Ever since people could tie logs together to form rafts and use them to transport goods by water, seaborne trade has flourished and grown. Historians believe that the first international trade routes were developed 5,000 years ago between the Arabian Peninsula and Pakistan, while by the 18th…

Health-tracking devices and apps are becoming part of everyday life. More than 300,000 mobile phone applications claim to help with managing diverse personal health issues, from monitoring blood glucose levels to conceiving a child.

But so far the potential for health-tracking apps to…

The spirit of service—for a small clinic started in 1913 to provide free care to Los Angeles (LA)—lives today in the servant-leader aspirations of 2019 Baldrige Award recipient Adventist Health White Memorial (AHWM), a 353-bed, safety-net hospital.

The community of two million people…

‘This government is obsessed with skilling up our population,” said Boris Johnson in his recent speech on “leveling up.” There’s still a fair amount of uncertainty about exactly what the United Kingdom prime minister’s plan to level up the regions will involve, but manufacturing and skills seem…

Due to digitalization in Industry 4.0, internal logistics is subject to constant change. Internal traceability—i.e., tracking goods in the warehouse or production facility—increasingly plays a key role. Manufacturers and consumers are placing more emphasis on the safety and quality of products.…

Lean Six Sigma has improved manufacturing operations and processes for years now. Now the effect of the methodology is extending to supply chain and operations to help eliminate waste and reduce variation. Using lean to eradicate waste and Six Sigma to eliminate defects by reducing process…

Effective equipment testing is essential for manufacturers of industrial equipment and end-users. Without testing, defects and damage can shorten the life span of equipment, cause unplanned downtime, and reduce the quality of finished goods.

This is especially true for businesses in…

Failure of a machine in a factory can shut it down. Lost production can cost millions of dollars per day. Component failures can devastate factories, power plants, and battlefield equipment.

To return to operation, skilled technicians use all the tools in their kit—machining, bending,…

The premise for the NIST MEP Digital Supply-Chain Network project is familiar to MEP centers—many small and medium-sized manufacturers (SMMs) are often not ready for Industry 4.0 and don’t know how to implement it. Manufacturers with fewer than 50 employees often lag in digital supply-chain…

Suddenly, supply chains are in the spotlight. The practical details of how products arrive on supermarket shelves, for example, gained unwelcome relevance amid last year’s wave of panic buying caused by Covid-19 disruption. At the same time, the environmental damage wrought by wasteful…

Seems everybody has a horror story about health insurance: Kafkaesque debates with robotic agents about what is and isn’t covered. Huge bills from a doctor you didn’t know was “out of network.” Reimbursements that take months to process.

It’s no secret that healthcare in the United…

During the last several decades, the ability to manufacture customized products for customers has become increasingly attractive to a growing number of companies. However, customization has led to manufacturers drowning in a sea of increasingly complex bills of material (BOM).

Standard…

Digital transformation is the integration of technology into all areas of a business, which fundamentally changes how organizations operate and deliver value to their customers. But what does success look like in a digital transformation? Project is on time and budget? Stakeholders are engaged…

Laser cutting is an essential part of many industries, from car manufacturing to construction. However, the process isn’t always easy or efficient. Cutting huge sheets of metal requires time and expertise, and even the most careful users can still produce huge amounts of leftover material that…

Product management as we’ve known it up until now—as a limited function or role—is effectively dead. However, viewed as a culture, product management is thriving. I predict “product culture” will be central to the future of work in digital economies. Yet knowledge workers, executives, and…

Industrial engineers design, develop, test, and evaluate integrated systems for managing industrial production processes. Functions include quality control, human work factors, inventory control, logistics and material flow, cost analysis, and production coordination. These and other facets are…

Like business-to-consumer (B2C) e-commerce, business-to-business (B2B) e-commerce allows customers to purchase parts and supplies via an online portal. The difference is that in B2B e-commerce, both the customers and suppliers are businesses, and the customers may or may not be the end users of…

Manufacturing robotics is to some extent following a similar path of advances to those in machining and fixed automation systems. Though the ROI is most easily measured in efficiency and cost savings, manufacturers are looking for robotic technology to help them resolve a pain point in their…

Lean supply chains are designed based on several key principles. First, the general philosophy of lean is to reduce or eliminate nonvalue-added waste. The concept of reducing waste is always beneficial to organizations. We should continuously strive to reduce things like wasted time, wasted…

A new study finds that productivity has remained stable or even increased for many companies that shifted to remote work during the coronavirus pandemic. However, innovation has taken a hit as both leaders and employees feel more distant from each other.

Businesses tend to spend less…

People will recycle if they can make money doing so. In places where cash is offered for cans and bottles, metal and glass recycling has been a great success. Sadly, the incentives have been weaker for recycling plastic. As of 2015, only 9 percent of plastic waste is recycled. The rest pollutes…

What is the most important thing for your business to be working on right now? Would everyone else working there agree? Is everyone working toward the business’s goals? How do you know?

Most businesses in my experience cannot answer these questions. There may be metrics, but they are not…

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…

Do you find the idea of having to do project management almost as much fun as getting a root canal? If so, you’re not alone. But it doesn’t have to be as bad as a painful dental procedure to adopt more effective ways of managing your projects.

Nor does it have to be extremely boring or…

Buildings account for about 40 percent of U.S. energy consumption, and are responsible for one-third of global carbon dioxide emissions. Making buildings more energy-efficient is not only a cost-saving measure, but also a crucial climate-change mitigation strategy. Hence the rise of “smart”…

Let’s pretend, for a moment, that you’re a primary care physician and you refer one of your patients to another doctor for a colonoscopy. Will the patient follow through? If not, how will your team know to remind him or her? If the patient does receive a colonoscopy, will your team be alerted so…

Any company that decides to enter the mattress business is no doubt entranced by one undeniable fact: Everybody needs one.

Those companies that start producing and selling mattresses also quickly run into a harsh fact: Everybody already has one.

Purple saw opportunity. It looked…

Research has shown that during economic uncertainty, companies that find a balance between reducing resources to survive and investing in key areas for growth will fare better through the recession and beyond. It’s a nuanced approach to playing offense and defense at the same time.

But…

The Covid pandemic has highlighted the role that manufacturing plays in our society. Manufacturing is important not only for improving our quality of life but also for the necessities of life, from food to toilet paper to transportation and safe and secure housing.  As our society has evolved,…

More than 80 percent of U.S. food manufacturing plants operating today were built more than 20 years ago and may lack safety features. The average age of manufacturing assets and equipment currently in operation in the United States, according to IndustryWeek, is close to 20 years, and since…

In order to best illustrate how enterprisewide SPC software can help address shop-floor problems and then funnel the captured data to the corporate level where strategic issues can be analyzed, here is a case study of a hypothetical manufacturing facility. In it, the company makes effective use…

Product development (PD) is the life blood of a company’s success and is the process for innovation. Today, product life cycles are shrinking due to an ever-increasing number of competitive and disruptive products coming to market quicker.

To stay in business, a company’s PD needs to…

The Covid-19 pandemic has revealed glaring deficiencies in the U.S. manufacturing sector’s ability to provide necessary products—especially amidst a crisis. It’s been five months since the nation declared a national emergency, yet shortages of test kit components, pharmaceuticals, personal…

The reality for small and medium-sized manufacturers (SMMs) is that they are going to have to be good at training their workforce or they won’t make as much money. That’s a blunt assessment, but the need for proficiency in training will only increase, whether it’s retraining current employees…

Freight trucks account for 23 percent of U.S. transportation. Transportation is the No. 1 source of greenhouse gas emissions in America. The country’s freight industry is in no position to ignore its impact on the environment and the greater good.

We can break down the trucking industry’…

We’ve all been in lines that seem to last forever, especially if we choose our queue at the checkout, and the one next to ours is moving faster. You know the existential dread that comes along with standing in a dedicated queue and waiting interminably. To make service of all kinds more…

In today’s coronavirus environment, governments at all levels are under greater fiscal pressure. For instance, Oregon’s governor has told state departments to prepare for a 12-percent reduction in their budgets. Given this environment, perhaps it is time to reexamine an established approach to…

The quote in the picture from Zora Neale Hurston does not end there; it finishes, “It is a seeking that he who wishes may know the cosmic secrets of the world and they that dwell therein.”

Zora was describing something specific in her life: researching folk music while she was…

The ongoing pandemic will likely change, if not completely alter, many aspects of our daily lives. One facet that will significantly change is the way we work. After months of being in lockdown, the massive shift to working from home has proven to be effective in helping employees stay…

Collaborative robots are increasingly attractive to manufacturers that require flexible solutions for their growing product mix but may not have the scale of work or capital resources needed to justify larger investments in automation systems.

These collaborative robots, commonly…

Despite juggling competing priorities, building resilient systems and processes within their organizations continues to be top of mind for business leaders today and is anticipated to be so for the foreseeable future. As such, the first logical step is to turn to existing methods and approaches…

In a recent survey, only 3 percent said they have confidence in corporate executives.

The news was equally dismal for others: 3 percent reported having confidence in government officials, 5 percent in reporters and journalists, 8 percent in small business owners, and only 11 percent in…

Step into the factory of the future. Alicia, an operations manager, sits at her workstation viewing a digitally enhanced video feed of the facility, using cameras installed in strategic locations. Wearing safety gear, a maintenance engineer named Bob checks his tablet for the next machine to fix…

‘Forward!” It’s the state motto of Wisconsin, where I work to help manufacturing companies improve their operations and processes. It’s one simple word that holds a lot of meaning and relevance. It’s what I want companies I work with to embrace, practice, and execute. Forward is a word that…

I’ve made it my personal crusade to keep a focus on the fundamental importance of productivity to manufacturers, to the Manufacturing Extension Partnership (MEP) program at the National Institute of Standards and Technology (NIST), and to the MEP centers that do the daily work of helping small…

Today’s manufacturers have plenty of software solution options that are meant to enhance their productivity. You may be familiar with each of these software packages. However, if you are not, it is important to understand what each of these software packages are designed to deliver.

…

Blame it on Moore’s law. We live in a digital Pangaea, a world of borderless data driven by technology, and the speed and density with which data can be transmitted and handled. It’s a world in which data-driven decisions cause daily fluctuations in markets and supply chains. Data come at us so…

It’s no secret that manufacturing companies operate in an inherently unstable environment. Every operational weakness poses a risk to efficiency, quality, and ultimately, to profitability. All too often, it takes a crisis—like Covid-19 shutdowns—to reveal operational weaknesses that have been…

During the first six months after the publication of its first edition in June 2019, the AIAG & VDA FMEA Handbook gained popularity in the global automotive industry. Both U.S. and European OEMs have started to require the AIAG VDA approach to failure mode and effects analysis (FMEA) in…

What is the Vasa? It was a Swedish warship built in 1628. It was supposed to be the grandest, largest, and most powerful warship of its time. King Gustavus Adolphus himself took a keen personal interest and insisted on an entire extra deck above the waterline to add to the majesty and comfort of…

When MIT announced in March 2020 that most research labs on campus would need to ramp down to help prevent the spread of Covid-19, Canan Dagdeviren’s lab was ready.

For the past two years, Dagdeviren and her lab manager, David Sadat, have run the Conformable Decoders Group using “lean…

When most people think of lean processes, they believe the goal is to optimize things in a step-by-step approach. The result that companies using lean methods can look forward to is incremental improvements brought about by the elimination of waste.

Individuals who stick with this…

Crossing the street or stepping backward when you encounter another person has already become a habit, as has a routine elbow bump, instead of a handshake.

And that is definitely what is needed during a health crisis. But when the time is right, as a society we must bounce back to social…

So many companies are shifting their employees to working from home to address the Covid-19 coronavirus pandemic. Yet they’re not considering the potential quality disasters that can occur as a result of this transition.

An example of this is what one of my coaching clients experienced…

Nobody likes business to be slow. If you’re in a fast-paced world like manufacturing, seeing your machines or employees idle can drive a person insane. If you’re used to your production line working to capacity and suddenly business slows down, it can be a frustrating time.

When I was in…

Even in the midst of the pandemic, product safety and quality remain critical. For many manufacturers, complex quality management systems and procedures stand in the way of agile responses and effective operational optimization. Cloud technology provides the means to dramatically simplify…

Each day we receive data that seek to quantify the Covid-19 pandemic. These daily values tell us how things have changed from yesterday, and give us the current totals, but they are difficult to understand simply because they are only a small piece of the puzzle. And like pieces of a puzzle,…

The Covid-19 pandemic has hit every industry with a barrage of challenges. The impacts on the manufacturing sector are already extending far beyond factory walls. And for now, the depth of those impacts and the expectation for recovery are unknown.

Fortunately, manufacturers are a highly…

When educational and public sectors consider applying a proven method like lean Six Sigma, the perception persists that this “manufacturing program” will not work in a nonmanufacturing environment. Along with that limiting assumption, there is an underlying expectation within the service…

Imagine a manufacturing facility prioritizing cleanliness and organization—aisles are kept clear, equipment is well maintained, the plant floor is regularly cleaned, operators can easily locate tools, and materials are always stored in the right place. All employees contribute to managing work…

This is supposed to be trade-show season. The time when companies send their employees to industry tech shows and user-group meetings to see and experience the latest offerings in their field. A time when companies expend a…

A large portion of a digital project manager’s job is making sure the right parts of the project are being worked on. Projects need to be prioritized. Tasks within projects need to be prioritized, too.

Plan View’s Project and Portfolio Management Landscape Report found that…

Each new year brings about a period of reflection, where one can think back on the path that the previous year took us on. 2020 represents an even larger opportunity for reflection as the world enters a new decade. Reflection provides an opportunity to learn and improve, and extends beyond just…

Almost half of Americans work in low-wage jobs despite the nation’s low unemployment rate. Aimee Picchi, writing for CBS News, cites a Brookings study that says “44 percent of U.S. workers are employed in low-wage jobs that pay median annual wages of $18,000.”1 A Bloomberg story adds, “An…

Perhaps for as many as 40,000 years, people have been protecting their feet with some type of covering, initially using animal hides and fur. Today, footwear has become high-tech, sophisticated, and in some cases smart, incorporating sensors that communicate with apps on your phone. Much of the…

Machine learning, the latest incarnation of artificial intelligence (AI), works by detecting complex patterns in past data and using them to predict future data. Since almost all business decisions ultimately rely on predictions (about profits, employee performance, costs, regulation, etc.), it…

‘It’s the shoes!” Spike Lee yelled into the camera on the Air Jordan ads.

But it was never the shoes. Michael, Magic, and LeBron would have outplayed their leagues in golf cleats.

It was never the shoes.

But it was us, the salespeople. In our case, the intelligencia…

Government bureaucracies are inefficient. They waste taxpayer dollars, and they have no incentive to improve. We’ve all heard and probably repeated these axioms about wasteful government spending.

And it’s often true; you don’t have to look far to find examples of government overpaying…

Lean: an employee-championed method of waste reduction. Six Sigma: a robust method of defect reduction. Embracing both methods provides organizations with multiple tools for continuous improvement. Developed for manufacturing, lean Six Sigma has now been recognized by government agencies as a…

At the University of California at San Diego, lean concepts have taken hold. Along with its process improvement curriculum, the university applies what it teaches through initiatives around campus. Projects both complex and simple tackle the snags, waste, and bottlenecks of academic life.…

Lean looks at ways to reduce waste and improve flow. The principles are relevant to virtually every organizational sector and vertical. It’s no surprise, then, that so many organizations tout lean and devote resources to lean initiatives. But, too often, there is a tendency for a company to…

Understanding the causes of faults and defects, and then improving the system or process so it won’t happen again, is central to lean manufacturing. This article looks at some of the methods used to identify the root causes of issues so that you can prevent downtime and move toward zero-defect…

‘Lean” is such a convenient term; everyone uses it based on their own definition. People frequently use “lean” in place of “efficiency,” probably because it sounds more cool. Another round of cost cutting? Sure, let’s tell everyone we’re “going lean,” again.

Lean is a proven, powerful…

The Automotive Industry Action Group’s (AIAG’s) and German Association of the Automotive Industry’s (VDA’s) new Failure Mode and Effects Analysis Handbook (AIAG, 2019) offers significant advances over FMEA as practiced 15 or 20 years ago.1 The publication is definitely worth buying because the…

‘I have been offered a significant increase in salary by another employer and am giving my two-week notice.”

My guess is that this is the most common reason given when employees quit their current job. But is salary the real reason most employees quit? I have always suspected and…

If you are wondering whether your organization could benefit from formal root cause analysis (RCA) and corrective action training, read on to see if any of these issues are present in your day-to-day operations. RCA and corrective actions are some of the most useful tools for continual…

As usual with Quality Digest’s diverse audience, this year’s top stories covered a wide range of topics applicable to quality professionals. From hardware to software, from standards to risk management, from China trade to FDA regulations. It’s always fun to see what readers gravitate to, and…

Eric, a 40-something married father of three, runs a successful startup. Given his demanding career, he and his wife decided she would be a stay-at-home mum. Eric believed the attention he devoted to his family was adequate, and that he had fully harmonized his work as CEO and life as a family…

When was the last time you as a quality professional saw a major failure in implementing decisions? What about in project or process management? Such disasters can have devastating consequences for high-flying careers and successful companies. Yet they happen all too often, with little effort…

Climate plans are the order of the day in the presidential primary campaign because carbon pollution is a global threat of unique proportions. But it’s worth asking whether candidates’ plans are based in the reality of the climate, the economy, and the election.

All three dimensions must…

Editor’s note: This is episode two in the Respect for People series. Click here for episode one.

When we build any working system, we need to understand and appreciate how people naturally exchange information. They withhold some things, say some other things. Some of this is fear, some…

How will the United States’ withdrawal from the Paris Agreement affect greenhouse gas emissions? Quality Digest editor in chief Dirk Dusharme and Mike Richman, principal at Richman Business Media Consulting, point out that most manufacturers already recognize that waste, including waste of…

Productivity matters. It matters a lot. Yet it often seems that folks talk about productivity but don’t do anything about it. At least, it feels that way to me when I go outside of the MEP National Network, where we’re always focused on enhancing manufacturing productivity. And you could say…

So it seems the contentious wall along our southern border, variously known as the Trump wall or the Mexico-United States barrier, isn’t meeting requirements. Walls keep people in; walls keep people out. They serve as backdrops for graffiti. But aside from fulfilling the last item, this wall…

A few years ago, I was asked to conduct a workshop, deliver a keynote, and chair a three-day conference on manufacturing process excellence in Europe, produced by the Process Excellence Network (PEX), a division of IQPC. Although that was a lot to ask of me, the lineup of speakers and content…

How would you like to go hands-free, maintain visual focus, and save time? These are just some of the benefits of using voice command to control machinery. Increasingly sophisticated natural language processing, based on artificial intelligence, also means that it is becoming possible to issue…

‘Why are our changeovers taking so long?”

If you’ve asked this question on the shop floor, more than likely you were met with blank stares by your employees. Open-ended questions like this are overwhelming, so employees try to find quick answers that don’t really address the problem.…

When I first learned quality improvement back in 1989 at Florida Power and Light, the consultants who trained us taught a very specific way to draw a Pareto chart. They’d been trained in Japan, the place where quality improvement first took root during the 1950s, so I took it for granted that…

Do you know what a retailer and a tightrope walker have in common? They both have to balance. For the tightrope walker, the logic is clear. But what’s the balance that a retailer is looking for?

Although the dilemma of shortages vs.…

According to a report by PwC, industrial sectors worldwide plan to invest $900 billion in Industry 4.0 each year. Despite these growing technology investments, only a few technologies are significantly mature to drive measurable quality impacts. Digital visual management (DVM) is one of them,…

Lean manufacturing is a philosophy focused on maximizing productivity and eliminating waste while creating a quality product. One of the most powerful strategies in the lean toolbox is total productive maintenance (TPM), a system targeting continuous improvement through a holistic approach to…

In the world of risk management, maintenance of mission-critical equipment drives priorities and budgets. It is the ultimate test of proactive maintenance and smart decision making. Managing assets that “cannot be allowed to fail” is more than an emotionally charged mandate that forces managers…

Operations management plays an important role in the manufacturing process, but similar to a stage crew at a theater, operations managers do all their best work behind the scenes. The best operations managers strive to go unnoticed, and why shouldn’t they? A seamless supply-chain process should…

About 10 years ago, software testing was perceived as the only possible quality assurance (QA) measure for software, according to the World Quality Report 2018–2019. However, QA has since outstepped these boundaries. The QA process now implies that all stakeholders have a direct interest in…

Most of us have heard of kaizen—continuous improvement of philosophy and methodology. In business, this involves all employees working to improve a company's processes to lean it out, to run with less waste. But most of us who are familiar with kaizen think of it as something you do.

…

Boeing has been rife with issues lately. While the recent Ethiopian Airlines crash has dominated headlines and elicited an FBI investigation into the company, another federal body has stated it will be keeping a closer eye on Boeing’s safety shortfalls.

Boeing is now in hot water with the…

If you have worked in the quality field for anytime at all, you have probably heard of the Malcolm Baldrige National Quality Award—it’s the highest level of national recognition for performance excellence that a U.S. organization can receive. The award focuses on performance in five key areas…

In the wake of the Lion Air and Ethiopian Airlines crashes of Boeing 737 Max planes, people are thinking about how much of their air travel is handled by software and automated systems—as opposed to the friendly pilots sitting in the cockpit.

Older commercial airliners, such as the…

Artificial intelligence (AI) is widely acknowledged as a crucial aspect of what is broadly referred to as Industry 4.0. Although no one knows yet how AI will be incorporated into the next phase of the Industrial Revolution, most agree that it will allow greater connectivity between people,…

For me, the operational essence of the leader dilemma is this: How do I say “yes” to the few and “wait” to the many? How do I decide?

The so-called “natural-born leader” is a mysterious (to some, controversial) concept: an individual for whom achievement, direction, and drive seem to…

Outsourcing is historically one of the most misunderstood concepts in quality management system (QMS) implementation and operation. Prior to ISO 9001:2015, the requirement for outsourced processes was limited to a few sentences in the standard’s clause 4.1. This article will present, through a…

The spring and summer of 2000 were a long time ago, but I learned some lessons during those months that have stayed with me. In fact, the learning from that experience is still happening as I continue to connect it to things I see today.

I was a member of a team working hard to stand up…

The role of quality starts with product design and moves rapidly across the supply chain to the selling and buying experience, which includes the bidding process. When operating a formal continuous process improvement program, nearly all manufacturing engineers are tasked with some level of…

Due dates. Whether it’s building a house or implementing an enterprise quality management software (QMS) solution, everyone has them, everyone wants them. What does home construction have to do with going live with a new QMS solution? There are actually quite a few similarities.

Happy New Year one and all! For our first QDL of 2019, we were pleased to present some thought-provoking content on the benefits of compromise, the dangers of rhetorical trickery, and the meaning of Chekhov’s gun. Let’s take a closer look:

Ripped from the headlines

Can’t…

We tied up last year in a neat little bow, talking about how stories define ourselves and our work; waste is waste, no matter your political leanings; and putting numbers from the news in context.

“The Gift of Being Small”

This article by Quality Digest’s Taran March…

As the global economy grows, it’s more necessary than ever to stay on top of efficiency. Keep up with increasing production demands by implementing a continuous improvement method to streamline the workflow.

Continuous improvement is an ongoing effort to improve products, services, and…

Even though most businesses have invested in quality management and performance improvement, each organization is unique. People, processes, and machines must be coordinated to achieve desired outcomes. This is not easy.

Whether you’re in discrete manufacturing, a process industry, or a…

The frequently referenced learning pyramid asserts than an average student retains 75 percent of information learned through practice, compared to just 5 percent of what he hears in a lecture. Although experts may dispute the relevance of these figures when applied to modern society, all of us…

Perhaps the reader recognizes d2 as slang for “designated driver,” but quality professionals will recognize it as a control chart constant used to estimate short-term variation of a process. The basic formula shown below is widely used in control charting for estimating the short-term variation…

Our industry embodies many aspects, but “Big Q” quality generally involves issues affecting management, measurement, and methodologies. This week on QDL, we covered all of them, and more. Let’s look closer:

“Ripped from the Headlines: Tariff Fallout”

U.S. manufacturers are…

During the late 1990s, I was working in the Silicon Valley for a medical device company, responsible for a drug-infusion pump manufacturing operation. I had just completed a crazy period where I had also “temporarily” (months and months...) led the advanced engineering department after that…

If you are a CEO of a manufacturing company with many value streams, it’s impractical to think that you have the time to review all the performance measures of every value stream in your company. Yet you need to know the operational impact of lean on your entire organization.

The…

In 2012, CMP Advanced Mechanical Solutions, a leader in the design and manufacture of sheet metal enclosures, mechanical assemblies, and machined systems, burst onto the Industry 4.0 scene with its avant-garde use of the visual work instruction software VKS. This software allowed the company to…

One of the highlights on our calendar each year is the first Friday in October, which is Manufacturing Day here in the United States. This event offers us the perfect opportunity to celebrate the centrality of manufacturing as a driver of the economy, innovation, automation, education, and lots…

LNS Research published its research, “Driving Operational Performance With Digital Innovation: Connecting Risk, Quality, and Safety for Superior Results” to address fundamental challenges quality and safety leaders face today. 

If quality and safety are separate functions in your…

Historically, quality in a process was something that was done at the end of the line. You inspected your widget once it was made, and if it had flaws, you fixed it or threw it out.

As in many modern manufacturing environments, quality in software has become a process you do from start…

In the foreword of Mark Graban’s book, Measures of Success: React Less, Lead Better, Improve More (Constancy Inc., 2018), renowned statistician, Donald J. Wheeler, writes about Graban: “He has created a guide for using and understanding the data that surround us every day.

“These numbers…

With more than 110,000 expected attendees, IMTS is Chicago’s hottest suburb this week. (I like to refer to it as “Manufactureville.”) Here’s what we covered during our second show of the week, from the booth of today’s sponsor, Q-Mark Manufacturing:

“Tapping Your Employee’s…

During a TED talk, Amy Edmondson, the Novartis Professor of Leadership and Management at Harvard Business School, talks about “How to turn a group of strangers into a team.” Although long-standing teams are able to perform, our workplaces today require ad-hoc collaboration between diverse groups…

Implementing 6S, the lean strategy for reducing waste and optimizing efficiency in a manufacturing environment, is more than just creating work protocols that people must follow. Because that’s the thing about people: If they don’t know the “why,” they are less likely to buy in to any initiative…

Founded in 1947, in Veles, Macedonia, BRAKO produces parts and components used in medical devices, road sweeper trucks, airport ground equipment, forklift accessories, metal-welded constructions, small hydro plants, telecommunications shelters, and antenna towers.

The company also…

As manufacturing finds its way through the 21st century, there’s a groundswell change emerging. Organizations are jockeying for competitive position as they endeavor to describe this phenomenon. Industry 4.0, the fourth industrial revolution, and the industrial internet of things (IIoT) are a…

‘In God we trust; all others bring data.” “Follow the data.” “Let the data talk.” Nice clichés, but there’s one problem... data can’t talk. In fact, data don’t say a darn thing. Data are bits of raw information. If you want to reduce product variation, improve your manufacturing processes, and…

Flow quality management (Flow QM) is a logistical alternative to handling product in lots for the purpose of assessing and mitigating defects. It features a streamlined, automated acceptance sampling methodology, is built on empirical metrics, and facilitates timely, meaningful performance…

Quality and manufacturing practitioners are most familiar with the effect of variation on product quality, and this is still the focus of the quality management and Six Sigma bodies of knowledge. Other forms of variation are, however, equally important—in terms of their ability to cause what…

As companies seek to gain efficiencies in the workplace, provide choice for employees, and attract and retain talent, strategies involving agile working and free-address have gained traction. When our Gensler La Crosse office relocated last year, we leveraged the opportunity to support an agile…

Although automation has been successful in replacing repetitive, simple tasks, the human workforce still plays a critical role in manufacturing. Even the most sophisticated and automated manufacturing operations rely on human operators to configure, run, and properly maintain production…

Does your organization benefit from lessons learned? Does it learn from previous quality issues? A vast amount of learning takes place every day in every manufacturing facility. Do global manufacturing companies share experiences gained from resolving quality issues between overseas plants? And…

Cogeco’s technical distribution center in Burlington, Ontario, is one of Canada’s drop-off points for internet modem and cable device repair. In 2011, the company’s management carried out a kaizen blitz to improve the efficiency of its device repair process. The process was indeed challenging…

Business partnerships are nothing new. Partnerships that result in leaner manufacturing processes, more consistent quality, and lower manufacturing costs—that is worth talking about.

With global competition so fierce, manufacturers must always be keen to spot areas of muda (waste). Even…

Boeing is demanding its suppliers reduce their prices by 10 percent, according to a February 2018 article published in Bloomberg Businessweek. It’s a hard pill for many to swallow, given that that these cuts are on top of the roughly 15-percent cuts demanded in 2012, when the company launched…

A couple of weeks ago I posed the question, “Are you overproducing improvements?” and compared a typical improvement “blitz” with a large monument machine that produces in large batches.

I’d like to dive a little deeper into some of the paradoxes and implications of 1:1 flow of anything…

Becoming a process-focused organization requires a sustained effort, and for most industrial and service organizations that is a difficult task. Failure to improve the performance of your processes leads to a failure to improve the organization and results in improperly managing the business.…

Imagine a factory with a large monument machine. It takes several days to set up. When it does run, it runs very fast, much faster than you can actually use its output. Therefore, you take the excess output and store it to use later. Actually, you don’t know how many items you need to make, so…

The rise of the independent worker is arguably the biggest change to hit the global labor market in decades. Well more than 30 percent of the United States workforce reportedly lack “real jobs” working full-time for a conventional company, and that figure, some say, may top 40 percent by…

According to the most recent report of the Economic Policy Institute, the average CEO-to-worker pay ratio in the United States has gone down from 286 to 1 (in 2015) to 271 to 1 (in 2016). This number may disappoint many top executives who were hoping to see it return to its peak of 383…

In part one of this article, we explored how Woodland Trade Co. (WTC) leveraged high-accuracy portable CMMs to help land tight-tolerance aerospace contracts, and even earn Boeing’s Supplier of the Year award. Here in part two, WTC’s QA manager William Shanks reveals the advanced technology that…

In a previous article I wrote about the reasons why so many lean manufacturing, Six Sigma, and other improvement programs fail. In this article I’m going to expand on reason No. 1: the Academy Award Syndrome.

The Academy Award Syndrome is where a…

Manufacturing activities have strong ties to economic prosperity. Deloitte’s 2016 Global Manufacturing Competitiveness Index states, “Nations and companies are striving to advance to the next technology frontier and raise their economic well-being.” It’s no surprise that the manufacturing sector…

Patients often wait weeks or months for medical appointments. Canada’s Fraser Institute recently reported that Canadians typically wait 10 weeks to see specialists. Long wait times are one reason Canada ranks behind other developed countries in healthcare quality.

In the United…

The sad truth is that the word “engagement” is not very engaging. It’s one of those fluffy, ambiguous terms that have become all too familiar around the business world, like “empowerment” and “respect.” What does engagement really mean, and how do you, as a leader, engage your workforce…

The global aerospace and defense (A&D) industry grew by 2.4 percent and generated about $674 billion in 2016, according to a Deloitte 2017 study. California alone was responsible for generating $62 billion a year in revenue in 2014, according to a 2014 California Aerospace Industry…

Industry 4.0, cyber-physical systems, or the internet of things (IoT): the paradigm shift in the production economy is cheerfully progressing under various names. What they all refer to is the digitalization and networking of production processes and environments. The idea is by no means…

People are always asking us for help with ways to prioritize. Almost everyone believes prioritization to be an action in and of itself. They ask, “What mechanisms do you use to prioritize?” However, we find most often that prioritization issues, like trust issues, are a symptom of deeper…

How does one define quality in the context of a warehouse? The perfect warehouse is clean, has everything in its place, and is easy to access. Your warehouse looks like the one below, right?

You have a perfectly accurate database table that tells you exactly where everything is,…

Lean, also known as “lean manufacturing” or “lean production,” focuses on maximizing customer value by removing waste and eliminating defects. Lean tools are about understanding the process, looking for waste, preventing mistakes, and documenting what you did. 

Let’s look…

During the past year, I stopped responding to customer surveys, providing user feedback or, mostly, contributing product reviews. Sometimes I feel obligated—even eager—to provide this information. Who doesn’t like being asked his opinion? But, in researching media technologies as an…

During the Nov. 3, 2017, episode of QDL, we (figuratively) traveled the globe to bring you quality information. Let’s take a closer look:

“‘Made in Japan’ Falls from Grace Amid Scandals, Systematic Flaws in Manufacturing Industry”

Kobe Steel is the latest Japanese…

The world first became aware of the Toyota Production System (TPS) when Taiichi Ohno published a book about his groundbreaking efforts at Toyota. It was published in Japan in 1978. The Japanese version of his book wasn’t translated into English until 1988. Because 10 years had passed,…

Quality tools can serve many purposes in problem solving. They may be used to assist in decision making, selecting quality improvement projects, and in performing root cause analysis. They provide useful structure to brainstorming sessions, for communicating information, and for sharing…

This photo shows the Milky Way (from the Latin via lactea), part of our galaxy as seen from Earth. It’s a barred spiral galaxy, essentially a flat disk of at least 100 billion stars. Our galaxy is just one of about 400 billion in the universe, only three of which can be seen by the naked…

I recently posted a version of the graphic below with the caption: “Not perfect, but close. It’s about right.” The response was overwhelmingly positive. A great majority of people recognized it as a unique comparison, one that they had never seen before, and also as an accurate…

While heading to a session at the most recent Lean Transformation Summit, I found myself confronted with signage that posed the following open-ended question: “All problem solvers must....”

Given how the work we do at Modus Cooperandi focuses largely on the nexus between lean for…

American Rheinmetall Systems (ARS) LLC, formerly Vingtech, is located in Biddeford, Maine. Established in January 2007, as part of a Norwegian company that had received a supplier contract for the U.S. Army’s CROWS remote weapon station program, the company was acquired by the…

QDL from Fri., Sept. 15, 2017, demonstrated that everywhere you look, you’ll find the positive effect of better quality. Here’s what we chatted about:

““U.S. Business Sectors Gain or Hold Steady in Public Esteem”

According to a recent Gallup survey, U.S. citizens’ outlook…

I had humble, that is, poor, beginnings. I didn’t even know the taste of real ice cream until later in life. One of the first impacts I felt of the luxury that technology brings was the diode my father bought for me to replace the cat’s whisker on…

Our August 11, 2017, episode of QDL looked at the role of technology in after-market service, stairs that help you up, Fidget Cubes, and more.

“Climbing Stairs Just Got Easier With Energy-Recycling Steps”

These stairs actually help you go up.

“The Curious Case…

Japanese improvement techniques have been emulated across the globe for decades, and none carries more cultural weight than the theory of kaizen. When I expose Western leaders to lean practices in Japan, they often express that they have come away with a better understanding of “true…

Completing the define phase of a lean Six Sigma (LSS) project is a critical part of any project, although it’s often underestimated in practice. The define phase of the define, measure, analyze, improve, control (DMAIC) process typically includes three elements. The first is selecting a…

The June 30, 2017, episode of QDL offered a wrinkle in time, of sorts: not only orbiting debris and medieval medicine, but moments in the here and now such as our interview with Keith Bevan of the Coordinate Metrology Society and the UK’s National Physical Laboratory, and an on-the-go version of…

Plant-floor quality issues tend to focus on a company’s technical resources. When products fall out of spec, alarms sound and all hands are immediately on deck to fix things. Despite large technology investments to monitor and adjust production processes, manufacturers are still…

To meet the 2018 deadline for becoming certified to ISO 9001:2015, organizations are scrambling to overhaul their quality management systems. One major revision to ISO 9001 is the requirement to identify, evaluate, and address risks. Unfortunately, a tool most appropriate for these…

Lean thinking has taken its rightful place in the effort to improve efficiency in manufacturing. However, it isn’t fulfilling its potential in many areas, most notably with knowledge workers. This is due to a fundamental flaw in how lean is presented and utilized. With a better…

Reading the Automotive Industry Action Group’s CQI-8 Layered Process Audit (LPA) Guideline, you might notice a line saying LPAs are “completed on site ‘where the work is done.’”

For lean manufacturing experts, this specific quote might bring to mind gemba walks, a method…

Sponsored Content

Founded in 1927 to produce aluminum splints—cutting edge at the time—Zimmer Biomet is a medical device company commanding second place in the entire world’s overall orthopedic market share. The organization’s stated purpose is to “…

In last week’s Quality Digest Live: Data for artificial intelligence, data for your quality management system, and Karl Popper meets Taiichi Ohno.

“Why AI Is the New Electricity”

Artificial intelligence will have the same impact on the world that electricty has.

 …

The American economy is underpinned by networks. Road networks carry traffic and freight; the internet and telecommunications networks carry our voices and digital information; the electricity grid is a network carrying energy; financial networks transfer money from bank accounts to…

The message for audience members who attended the 29th Annual Quest for Excellence Conference held last week was, “Prepare for an inspiring journey.” This was the advice of keynote presenter Polly LaBarre, co-founder and director of Management Lab (MLab) and co-founder of Management…

Digital disruption is reaching beyond technology to engulf a variety of industries, including manufacturing, transportation, energy, healthcare, and construction, that constitute a significant portion of the global economy. Manufacturing alone accounts for 12 percent of the U.S. GDP,…

Sponsored Content

Brian Vinson may have one of the best jobs in the country. Vinson works as director of engineering with AWE Tuning, an automotive aftermarket company that provides award-winning, handcrafted performance exhausts, track-…

In this week's Quality Digest Live: Lean Ben Franklin... who knew? Could the root cause of some manmade catastrophes simply be a lack of basics like humility, integrity, communication, and positivity? Connected spenders is what you want. And what’s the most important question to ask about your…

One of the most important goals of lean manufacturing is the elimination of waste. Taiichi Ohno, father of the Toyota Production System (TPS), defined three categories of waste: mura, muri, and muda. While muda is the most widely known, muri and mura are equally important to understand…

For several decades, manufacturers have been pursuing lean on their shop floors to reduce costs and improve lead times through waste elimination and process improvement. They have been less successful, however, in reaping lean’s potential benefits in their purchasing, planning, and…

Recently, during one of my many adventures across the internet, I stumbled across a photo that struck me. It depicts an aisle of a U.S. drugstore, where nearly every single product facing has a tag on it announcing a price and a limited-time promotion. The entire row is covered with…

I have been inspired to write this article after learning about Joseph Juran and understanding the effect he has had on our society. I started working at Juran Global about six months ago, and since then I’ve had several friends and past colleagues reach out to me with questions like, “…

Change is inevitable in every organization. Planned or not, forces inside and outside the enterprise can sometimes encumber a workforce and lead to nonvalue-added processes. Growing spurts, major technology implementations, or even small supply-chain organizational projects can present…

Sponsored Content

Like many manufacturers, boat maker Smoker Craft has enormous amounts of data. The challenge, according to Quality Assurance Manager Dave Frey, was that all the data were on…

Sponsored Content

When flood waters ravaged portions of Colorado in September 2013—killing crops, inundating homes, and buckling many miles of roadways—countless federal, state, and municipal government workers sprang into action helping citizens. State…

Healthcare professionals have a long history of caring for their patients and improving the quality of their services. During the Crimean War (1853–1856), British nurse Florence Nightingale realized that the mortality rate of soldiers was far too high. A visionary statistician as well as…

Industrial companies are facing critical challenges rooted in slow growth, globalization, the effect of disruptive technologies, and unforeseen competitive threats. A new report from global management consulting firm, L.E.K. Consulting, reveals how those companies are responding—and what…

Manufacturers’ waste-reduction initiatives are rarely as effective as they could be. When reducing waste, inventory is often the main target. But how do you right-size inventory in an environment of constant variability? In a word: kanban.

Electronic kanban signals keep product…

Ellis Medicine is a 438-bed community and teaching healthcare system serving New York’s capital region. With four main campuses, five additional service locations, more than 3,300 employees, and more than 700 medical staff, Ellis Medicine offers an extensive array of inpatient and…

The proliferation of Accountable Care Organizations (ACO), spurred by the healthcare industry’s shift from fee-for-service to pay-for-performance, has focused healthcare executives’ attention on clinical outcome metrics. Yet the greatest barriers—individual clinician practices—remain…

While commanding four vessels sailing between England and India in 1601, Capt. James Lancaster performed one of the great experiments in medical history. Each of the seamen on just one ship—his own, of course—was required to sip three teaspoons of lemon juice per day. By the midpoint of…

Sponsored Content

You might say what Henry Ford did for the automobile, GE, Siemens, and Mitsubishi have done for the gas and steam turbine industry. Naturally, the tools and technicians of both sectors have had to evolve right along with the challenges of new…

As organizations become successful and grow, uncertainty is generally the enemy. Thriving organizations seek to eliminate variation and increase efficiency. They identify best practices and policies, and design standard operating procedures. Such efforts can make a business wildly…

New technologies have empowered customers to seek out the best products and services at the lowest cost and shortest delivery times. Customers can compare price and delivery information as well as reviews about product quality. Thus, the importance of sustaining outstanding quality in…

Here’s a stat that might surprise you—according to LNS Research, 50 percent of manufacturers have implemented or will be implementing cross-functional groups to support their operational excellence journeys within a year. At the same time, only 18 percent have software or processes in…

Sponsored Content

For more than 30 years, Hendrick Motorsports has consistently been one of NASCAR’s most successful teams. In the course of winning a record 11 Sprint Cup Series championships, Hendrick Motorsports has learned that it must innovate…

The world is using its natural resources at an ever-increasing rate. Worldwide, annual extraction of primary materials—biomass, fossil fuels, metal ores, and minerals—tripled between 1970 and 2010. People in the richest countries now consume up to 10 times more resources than those in…

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…

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…

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…

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…

Sponsored Content

In the most basic terms of engine exhaust theory, more flow equates to more performance. The aim is to improve the efficiency of your vehicle’s engine, boost performance, and save money on fuel…

It’s amazing that, in this day and age, some manufacturers have not yet heard of “lean.” How are they surviving in today’s competitive market without it? The issue is that, in many ways, the customer sets pricing. If manufacturers want to be profitable, they must find ways to become more…

Sponsored Content

PLZ Aeroscience is North America’s largest custom aerosol manufacturer and packager. It produces its own private-brand products and custom formulations, and provides contract filling for other customers. PLZ has been in business for…

Editor’s note: This is an excerpt from the book, Management Lessons From Taiichi Ohno: What Every Leader Can Learn From the Man who Invented the Toyota Production System, by Takehiko Harada (McGraw-Hill Education, 2015).

The phrase, “kaizen equals getting closer to the final…

Visual scheduling is a plain, two-dimensional format that maps out which products, parts, or subassemblies need to be produced, and when, in what quantity, and in what order. Nothing could be simpler.

In companies where schedules aren't published in a single, centralized location…

We are all cursed with “surprises” at work. We come in, sit down, get ready for the day. We select a task to start on, and about halfway through, it explodes on us. The seemingly simple task now has 30 subtasks all lined up, ready to destroy our day.

This is stressful. Since we’…

Today I’d like to talk about kaizen—specifically, the order for kaizen. The term has come to mean “continuous improvement,” but kaizen originally translates from Japanese as “change for better.” To help clarify this useful concept, I’ll present three different views for approaching…

One poorly understood concept in lean Six Sigma is how much to “stretch” when setting S.M.A.R.T. goals. These letters are defined as S—specific; M—measureable; A—assignable, attainable, or achievable; R—realistic, reasonable, or relevant; and T—time-based or time-bound. Regardless of the…

Editor’s note: This is an excerpt from the new book, Innovating Lean Six Sigma, by Kimberly Watson-Hemphill and Kristine Nissen Bradley.

Like every company, healthcare businesses do their work through processes, and any process can be studied and improved using basic lean Six…

In March 2011, Leonardo Bonanni was preparing to defend his Ph.D. thesis about Sourcemap, software that lets consumers map every connection of a product supply chain on a digital map, when tragedy struck in Japan. Although the deadly earthquake and tsunami occurred half a world away, the…

The start of a failure investigation may involve brainstorming, but empirical methods will be required to actually identify a problem's cause. Implementing an improvement action without a confirmed root cause risks a reoccurrence of the issue because the true root cause has yet to be…

Many of our most popular stories of discovery are portrayed as accidents or matters of luck. We love these stories because they make creativity seem easy and fun. Nevertheless, they are misleading.

In a recent New York Times opinion piece titled “How to Cultivate The Art of…

Sponsored Content

I can tell you all about the California coast, its cultural and economic dynamics, my favorite hideaway beaches and eateries, and I can attest to the wisdom of never turning your back to the surf. I know these things…

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…

Reducing waste, implementing efficiency-promoting practices, and continuously improving operations are the main goals of lean manufacturing ideology. These tasks may seem daunting for a manufacturer at the start of an improvement program, but there are many concrete steps that can be…

The foundation of lean manufacturing is kaizen, or continuous improvement. Although this principle usually targets manufacturing processes, it can also extend to the people who plan and implement lean projects—individuals that grow professionally and personally as a result of new skills…

Chances are you are not fully satisfied with the results of your lean initiatives. It’s also likely that lean thinking is not used to improve your employees’ skills in working together. That’s because you are using only half, probably less, of the power of lean thinking.

…

One of the most challenging issues I hear from people within the lean Six Sigma community is how to ensure that a lean Six Sigma project is sustainable. If your lean Six Sigma project is highly dependent on top leadership support to keep it going, there’s a risk of losing the focus and support…

Value stream or other lean analysis helps identify the main obstacles to  flow in a process. Improvement projects using lean tools in a transactional environment (i.e., office) are often confronted with the following problem: Lean teams lack a methodology to consistently problem-solve how to…

Some time ago, while consulting for a huge call center, I took a group of customer service agents for a little gemba walk and a quick activity to demonstrate a few lean fundamentals. What was scheduled for a 60-minute exercise turned out to be an experience that awakened the agents, several of…

The 5 Whys is a well-known root cause analysis technique that originated at Toyota and has been adopted by many other organizations that have implemented lean manufacturing principles. Unlike more sophisticated problem-solving techniques, the 5 Whys doesn’t involve data segmentation, hypothesis…