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MB with Erausquin and Roberto

Jun 30 2012

Role of Management in Lean (In Spanish)

See on Scoop.it – lean manufacturing

Interview published in March, 2012.

It was prepared with your help, in the following posts:

  • What if the role of a manager in leading the implementation of Lean?
  • What does a manager need to know  to undertake a Lean transformation?
  • What are the key behaviors for Managers to ensure a consistent Lean implementation?
  • What support infrastructures do you need for Lean?
  • What visible actions should managers take to support Lean?

Thanks for the many comments.

See on www.apd.es

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By Michel Baudin • Press clippings 0 • Tags: Lean, Management

Jun 28 2012

Metrics on the web versus manufacturing

Mingled last night with 209 internet operations “ninjas” at the meetup of the Large Scale Production Engineering (#lspe) group, on Actionable Metrics, hosted by Yahoo! in Sunnyvale, CA,  and heard speakers from collectibles marketplace site etsy, web performance testing service SOASTA, and video streaming service Netflix describe how they used metrics in their activities.

Both in style and content, the presentations were radically different from what I have heard in manufacturing on that subject. The speakers went fast, as if they were in a great hurry to give us as much information as possible prior to returning to work. They were also extraordinarily open about the tools they used and how they used them.

The first feature of their work that struck me was the simplicity of their dashboards. Almost all the charts they monitor are simple line plots of time series, free of the jumble of 3D pie charts, stacked bar charts, and other complicated displays commonly found on manufacturing dashboards.  The most elaborate display showed a time series of, for example, login response times, with a dynamically adjusted confidence band based on a statistical model to help operations engineers tell significant changes from fluctuations. Yet, even with these features, the meaning of the chart was obvious, even to an outsider to their business. It is not difficult, for example, to understand a plot of the evolution of login times as the number of users grows or additional security is added.

As engineers tweak and enhance the functions provided on their servers everyday, they monitor metrics to see if it does any good, and take immediate action if it doesn’t. The time within which they can and must react is measured in seconds, not hours or days. Their metrics fall into the following categories:

  1. Customer experience/business. This includes the user experience and its translation into business activity, like the number of page views and the conversion ratio of page views to orders. For a subscription-based service like Netflix, it might include the number of times subscribers visit the site without streaming anything, suggesting that they didn’t find what they were looking for.
  2. Infrastructure. This covers the behavior of the servers and the networks through which user inputs are passed to the applications and outputs returned. This has to do with processor and memory utilization, and with the availability of these resources in the face of very large and varying numbers of user interactions.
  3. Application. These metrics rate the ability of the application software to process the user data once it has them and until it sends a response. This includes the speed and quality of concurrent searches or commercial transactions, or the protection of user data.

Customer experience translates as is to a manufacturing context but Infrastructure, on the other hand, corresponds to Logistics, and Application to Production all with different time scales. While one of the speakers described response time as “one metric to rule them all,” none of the organizations presenting imposed any standard set of metrics on their engineers. Instead, they provide them with tools to capture the data, compute the metrics, display them on charts, and generate alerts, but it is their choice and their responsibility to define the metrics.

Response time is to their world what order fulfillment lead time is in manufacturing, but its importance is much greater. There are sectors in manufacturing where short order fulfillment lead times are a competitive advantage with customers, but also many, particularly with big ticket items, where other factors trump short lead times. If you are a farmer buying a tractor, for example, you will take one with the features you want over one you can have sooner that doesn’t have them. The pursuit of short production lead times has to do with other considerations, such as reducing inventory, detecting quality problems faster, or reducing the obsolescence cost of engineering changes. When providing services on the web, on the other hand, any slowdown in response causes customers to balk, and, internally, any increase in transaction processing time can cause servers to saturate and customer response times to explode.

For these engineers, capturing one metric is a matter of adding one line of code in their software, and they use open-source tools to generate plots and dashboards. It is not difficult to do. The hard part  is identifying the right metrics. The Netflix speaker was quite aware of this. After someone had him “No matter what you measure, it’s useful,”  he charted the evolution over one year of the proportion of user IP addresses ending with an even number.

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By Michel Baudin • Metrics 1 • Tags: Metrics

Jun 27 2012

Mark Graban on Kaizen in health care

See on Scoop.it – lean manufacturing

Author encourages kaizen methods to improve healthcare (San Antonio Express) The book, published Wednesday, highlights lean management practices, which focus on methods of daily continuous improvement, or “kaizen,” for healthcare …and more »…

See on www.mysanantonio.com

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By Michel Baudin • Press clippings 0 • Tags: Health care, Kaizen, Lean

Jun 27 2012

What the gizmos are for at Chrysler’s WCM academy

Chrysler’s recently opened “World Class Manufacturing” (WCM) academy in Warren, MI, uses a number of high technology tools, including a 3D immersion theater, the motion-tracking suits used in video game design, and a modified slot car track. To figure out what they are used for, however, we need to piece together separately published information from the Kelley Blue Book’s Car News from 1/24/2012  and the  1/30/12 issue of the  UAW’s Solidarity magazine,

The 3D immersion theater

From Car News, this is what it looks like:

According to Solidarity magazine, it is used for safety training, as follows:

Students don 3D goggles to become fully immersed in a plant setting full of unsafe acts and conditions, thanks to the same technology used by the U.S. Department of Defense to train soldiers deployed to Afghanistan.

The video becomes a learning tool to help workers become aware of unsafe conditions, identify potential hazards and work through possible solutions.

Motion tracking suits

From Car News:

From Solidarity:

…the Human Motion Capture Arena employs the same technology used to create video games in an exercise designed to improve efficiency in performing job functions.

A student dresses in a special suit covered with LED sensors that capture the individual’s movements, from the largest such as walking to the slightest such as the movement of a finger. Above, a ring truss is equipped with multiple cameras that capture the movements and project them on a video display.

This exercise enables students to visualize how an operator would move to perform a given job function so they can eliminate waste by deciding how to reduce the number of movements or make them more consistent with a person’s natural movements.

The slot car track

From Car News:

From Solidarity:

The slot car track is used to demonstrate the seven steps of micro-stoppages on the line – small equipment breakdowns that can cause major losses.

The cars on the track and the track itself have been modified to “break down” while racing. A high-speed camera captures the movements, helping students see that the breakdown might be worse than what is obvious to the naked eye. In this way, operators learn to apply a disciplined process to discover the root cause of a problem.

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By Michel Baudin • Press clippings 0 • Tags: WCM, World Class Manufacturing

Jun 25 2012

Chula Vista leans on private industry

See on Scoop.it – lean manufacturing

How the city government in Chula Vista, CA, got help from the local Goodrich Aerostructures plant to start a Lean program in its own operations.

See on www.utsandiego.com

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By Michel Baudin • Press clippings 0 • Tags: Government, Lean implementation, Toyota Production System

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