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LegoTractorCitySet

Jul 29 2020

The BOM Rap (Part III) — Scaling Up

The BOM Rap recommended restricting the centrally managed part of the Bill Of Materials (BOM) of an assembly plant to the Gozinto (“goes-into”) structure of the items. Building on this, Part II used a small toy example to introduce the Vàzsonyi procedure as a tool usable on a laptop computer to extract useful information from BOMs for use in assembly improvement projects, together with graphic visualization tools.  Here, we apply these tools on the larger, more realistic BOM, of the Legotractors from our Leanix games.

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By Michel Baudin • Information Technology • 0 • Tags: Bill of Materials, BOM, Gozinto, Master Data Management

AndrewVazsonyiThreeAges

Jul 9 2020

The BOM Rap (Part II) — The Vàzsonyi procedure

The BOM Rap recommended restricting the centrally managed part of the Bill Of Materials (BOM) of an assembly plant to the Gozinto (“goes-into”) structure of the items — that is, triplets with an item ID, the ID of an item it goes into, and the quantity used, together with an item list carrying units of measure.

This is the common core to all uses of the BOM, to which engineers, production planners, or accountants can attach additional data for their own purposes.

As discussed in The BOM Rap, BOMs are usually kept in ERP systems that only support their uses in their transaction menus, and production engineers often need to do more.

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By Michel Baudin • Information Technology • 3 • Tags: Bill of Materials, BOM, Master Data Management

May 28 2020

“Herd Immunity” Varies With The Herd

New York Times article presents herd immunity as independent of population

In today’s New York Times, N. Popovitch and M. Sanger-Katz wrote an article about how The World Is Still Far From Herd Immunity for Coronavirus, in which they treat herd immunity as if it were a characteristic of the disease only, achieved when 60% of the population has antibodies.

The CDC On Herd Immunity

The US CDC website defines herd immunity it as “a situation in which a sufficient proportion of a population is immune to an infectious disease (through vaccination and/or prior illness) to make its spread from person to person unlikely.”

The CDC  makes it clear is that the “sufficient proportion” depends on both the disease and the population in which it spreads. In other words, for a given disease herd immunity varies with the herd. The same proportion of immune individuals will not achieve it in populations with different lifestyles. It is higher if they commute in crowded buses to work shoulder-to-shoulder on assembly lines; lower, if they move in individual cars and work in private offices.

The CDC’s definition fails to say what they mean by unlikely. To reopen factories without making them COVID-19 hot spots, we need the workforce to have herd immunity. It means that its members must be unlikely to infect each other, not that 60% of them must have immunity.

Herd Immunity In The SIR Model

Two of the charts from my previous post on this subject can clarify the issues. The first one shows the generic pattern of an epidemic over time in a population, in the classic SIR model.

The key parameter often mentioned today by people like Angela Merkel is R_{0} , pronounced “are-nought,” which can be interpreted as the expected number of people an infected person would transmit the disease to while infectious in a population where no one else is infected. In a population of size N The number of infected people peaks when the number S of susceptible individuals drops enough to have R_{0} = N/S . Some authors call the ratio r = 1- S/N of recovered people to the entire population at the peak of the epidemic the “herd immunity threshold.” Past this point, the epidemic ebbs, but infection can still be likely.

At the right side of the curve, where the number of infected people drops to 0 , the limit r_{\infty} of r varies between 0% and 100% depending on R_{0} . r_{\infty} describes the proportion of the population with acquired immunity that is necessary to confer herd immunity on the entire population. You don’t have to say how unlikely transmission is.

r_{\infty} is a final score directly observable only when the epidemic is over. R_{0} , on the other hand, can be estimated early on, albeit with wide margins of error. With a model of the epidemic,  r_{\infty} can then be inferred from R_{0} .  The second chart plots s_{\infty}  = 1- r_{\infty} as a function of R_{0} in the basic SIR model, with the ranges of R_{0} estimates published for the seasonal flu and COVID-1.

When The Population Is The Workforce Of A Factory

All the practices introduced into a factory to prevent contagion at work lower the R_{0} of the disease within the workforce while working, which lowers both the herd immunity threshold and the level of actual immunity required to achieve herd immunity in the long run, and this is quantifiable.

Of course, outside of work, the employees of the factory are within society at large. They are subject to its contagion dynamics. The main problem of today, however, is factories turning into epidemic hot spots.

#herdimmunity, #covid19, #factoryreopening, #factoryhotspots

 

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By Michel Baudin • Press clippings • 0 • Tags: COVID-19, Factory Hot Spots, Factory reopening, Herd immunity

May 8 2020

A Lifetime Of Systems Thinking | Russell Ackoff | Systems Thinker | June-July, 1999

Russell Ackoff

While this article is from 21 years ago and about systems thinking, Ovidiu Contras felt compelled to share it on LinkedIn today, because of the following quote:

“My fourth source of fun has been the disclosure of intellectual con men—for example, propagators of TQM, benchmarking, downsizing, process reengineering, and scenario planning. Managers are incurably susceptible to panacea peddlers. They are rooted in the belief that there are simple, if not simple-minded, solutions to even the most complex of problems. And they do not learn from bad experiences. Managers fail to diagnose the failures of the fads they adopt; they do not understand them…. Those at the top feel obliged to pretend to omniscience, and therefore refuse to learn anything new even if the cost of doing so is success.”

Source: Systems Thinker, June-July, 1999

Michel Baudin‘s comments:

“Lean” is not in the list of panaceas. Before finding solace in this omission, however, we need to consider the vintage of the article. It’s from 1999, when flip phones were cool. Writing today, the author might have included Lean, Six Sigma, Lean Six Sigma, TOC, Agile, and, on the other hand, omitted dead horses that have long been buried.

While the “belief that there are simple, if not simple-minded, solutions to even the most complex of problems” is certainly mistaken, the approaches peddled as panaceas sometimes contain nuggets of wisdom applicable to specific problems. The mistake is to go global cosmic and promote them outside their range of applicability. My own comparative analysis is from 2013, and would also need an update to include the more recent panaceas.

Reading the whole of Ackoff’s article, I had no issue with most of his points but a few stood out, about which I had a few comments. Russell Ackoff, unfortunately, died in 2009 and won’t be able to reply.

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By Michel Baudin • Press clippings • 2 • Tags: Systems thinking

RanchoSanAntonioPlacard

May 6 2020

The Math of COVID-19, And Factories

Whether we like it or not, the past months have given us a crash course in epidemiology. COVID-19 has taken terms like reproduction number, herd immunity, social distancing, or flattening the curve from research literature to daily news and instructions for visitors to California State Parks.

We are in the middle of a pandemic we have partially tamed by putting the economy in a coma. This pandemic has already killed more Americans in two months than the Vietnam war in 20 years and we are facing the unprecedented challenge of restarting factories in this context.

Among the many things to learn in a hurry, are what epidemiologist Adam Kucharski calls the rules of contagion, as they apply to the people who work in a factory and its surrounding community.

Quality control is the closest most of us in Manufacturing ever get to serious statistics/data science. It’s not the same domain as epidemiology, and there is little crossover in tools or methods. This is to share what I have just learned about this topic. I welcome any comment that might correct misconceptions on my part or otherwise enlighten us.

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By Michel Baudin • Data science • 3 • Tags: #Flattening the curve, COVID-19, Cycle testing, Epidemiology, Restarting factories

Apr 30 2020

The Impact Of Social Distancing On Assembly Operations | John Shook | LEI

 

Testing temperature measurement setup

“Problems and Countermeasures at GE Appliances and Herman Miller:

  • Problem 1: Clarify what is the problem to solve 
  • Problem 2: Ensure each member is coming to work healthy 
  • Problem 3: Make assembly line work safe for social distancing 
  • Problem 4: Maintain social distance for Team Leader Andon response 
  • Problem 5: Apply social distancing to other, non-assembly line, work areas 
  • Problem 6: Resolve the many other safety concerns that are cropping up 
  • Cleaning surfaces 
  • Cleaning air – Ventilation 
  • PPE
  • …”

Source lean.org

Michel Baudin‘s comments:  John Shook’s writings are usually more polished. This one feels like notes from conversations with managers from GE Appliances (GEA) and Herman-Miller (HM). It goes straight into the heart of the matter with no lead or introduction and with acronyms that are not defined but easy to decypher, like “TT” for Takt Time. This tone actually infuses the article with a sense of urgency. It reads like an unvarnished look at what is actually happening and it contains many informative photographs of the shop floors.

For each problem, GEA and HM give pointers on making assembly work safe from COVID-19 but I have a few questions the article does not address:

  1. How do you protect assembly workers from infection through the products? Social distancing protects them from each other’s breaths but an infected worker’s hand can contaminate a workpiece. The workpiece can then, in turn, infect the next worker’s hand. The article does not discuss means of disinfecting workpieces between stations.
  2. What does distancing do to assembly operations? For decades, we have been bringing workstations closer together, to make it easier for operators to help each other and run multiple stations when the volume is lower. Now, we have to go in the opposite direction.

#socialdistancing, #assembly, #leanmanufacturing, #covid19

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By Michel Baudin • Blog clippings • 1 • Tags: Assembly, COVID-19, Lean manufacturing, Social distancing

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