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Jan 1 2018

What’s Going On In German Companies | Bodo Wiegand | Wiegand’s Watch

Bodo WiegandBodo Wiegand heads Germany’s Lean Management Institute. In his latest newsletter, on Wiegand’s Watch, he explains his concerns about the future competitiveness of German companies. Here is my full translation of his article, followed by my comments:

Bodo Wiegand: “A huge potential is not realized and simply left fallow – can we really afford that?

I think we cannot afford it.

In China and India, more engineers are trained each year than we have in Germany in total, and then we fail to exploit the huge potential of the engineers we have. Why? Because we do not want to give up our fiefdoms, our functional thinking and our single-minded concern for our turf.

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By Michel Baudin • Blog clippings 3 • Tags: Germany, Information technology, IT, Office Productivity

Dec 10 2017

Is SPC Obsolete? (Revisited)

Six years ago, one of the first posts in this blog — Is SPC Obsolete? — started a spirited discussion with 122 comments. Reflecting on it, however, I find that the participants, including myself, missed the mark in many ways:

  1. My own post and comments were too long on what is wrong with SPC, as taught to this day, and too short on alternatives. Here, I am attempting to remedy this by presenting two techniques, induction trees and naive Bayes, that I think should be taught as part of anything reasonably called statistical process control. I conclude with what I think are the cultural reasons why they are ignored.
  2. The discussions were too narrowly focused on control charts. While the Wikipedia article on SPC is only about control charts, other authors, like Douglas Montgomery or Jack B. Revelle, see it as including other tools, such as scatterplots, Pareto charts, and histograms, topics that none of the discussion participants said anything about. Even among control charts, there was undue emphasis on just one kind, the XmR chart, that Don Wheeler thinks is all you need to understand variation.
  3. Many of the contributors resorted to the argument of authority, saying that an approach must be right because of who said so, as opposed to what it says. With all due respect to Shewhart, Deming, and Juran, we are not going to solve today’s quality problems by parsing their words. If they were still around, perhaps they would chime in and exhort quality professionals to apply their own judgment instead.
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By Michel Baudin • Data science 3 • Tags: data science, Quality, SPC, Statistical Process Control

Nov 24 2017

Now It’s Humans Assisting Robots | Sheelah Kolhatkar | The New Yorker

Steelcase ology

“[…]As a zone leader, Stinson is responsible for about fifteen employees on a section of the production line that makes parts for Steelcase’s Ology series—height-adjustable tables built for the standing-desk craze. Until last year, the plant workers had to consult a long list of steps, taking pains to remove the correct parts out of a cart filled with variously sized bolts and screws and pins and to insert each one in the correct hole and in the correct order. Now computerized workstations, called ‘vision tables,’ dictate, step by step, how workers are to assemble a piece of furniture. The process is virtually mistake-proof: the system won’t let the workers proceed if a step isn’t completed correctly. We stood behind a young woman wearing a polo shirt and Lycra shorts, with a long blond ponytail. When a step was completed, a light turned on above the next required part, accompanied by a beep-beep-whoosh sound. A scanner overhead tracked everything as it was happening, beaming the data it collected to unseen engineers with iPads.[…] ”

Sourced through The New Yorker

Michel Baudin‘s comments: This is excerpted from a long article entitled Welcoming Our New Robot Overlords, from the 10/23/2017 issue of The New Yorker that caught my attention because it’s not about robots and it seems to be in the same spirit as Omron’s Digital Yatai back in 2002: using technology to eliminate hesitation and to mistake-proof operations that are too long or have too many variants to allow operators to go “on automatic” while performing them.

When repeating the same 60 seconds of work 400 times in a shift, operators quickly develop the ability to execute rapidly and accurately with their minds elsewhere. If on the other hand, the takt time is 20 minutes or the work is customized for every unit, the work requires the operators’ undivided, conscious attention and their productivity is increased by systems like the vision tables described in the article, that prompt them for every step and validate its completion.

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By Michel Baudin • Press clippings 0 • Tags: Automation, Autonomation, Digital Yatai, jidoka, robots

Nov 22 2017

Why do we call it “value stream”?

On LinkedIn, Dinesh Vasandani, Director of industrial engineering and manufacturing operational excellence at Boeing, asked “Why do we call it value stream? Most value streams have minimal value added work rates. Should we start calling them waste streams?”

To date, Dinesh has had responses from, besides myself, the following: Humaid Abubakar, Ray Ardahji, Andrew Brown, Mauro Cardenas, Evaristo Dominguez, Prakash Gadhar, Jacqueline Hartke, Jun Nakamuro, Salvador D. Sanchez, Mark Searcy, Oliver Tamis, Ravi Vaidiswaran, Matt Wehr.

Toyota alumnus Salvador Sanchez was first to point out that Toyota doesn’t use the term “value streams,” which was echoed by other past and present Toyota employees, like Evaristo Dominguez and Ray Ardahji.

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By Michel Baudin • Blog clippings 3 • Tags: Toyota, TPS, Value Stream, Value Stream Mapping, VSM

Nov 12 2017

How Hard Is It To Create Flow?

Mark DeLuzio

Mark DeLuzio started a discussion on LinkedIn with the following question:

“My Sensei Mr. Nakao once told me: ‘The hardest thing to do in TPS is to create flow.’ What do you think about that?”

It started a spirited debate, with the following participants, in alphabetical order: Bruce Andersen, Rob Beesley , Vincent Bozzone, Mark DeLuzio, Michael Dunne, Okan Gurbuz, Shahrukh Irani, Kerry McPherson,, Gregoire Nleme, Okan Gurbuz, Egidijus Karitonis, Sunil Malagi, Paul Van Metre, Jerry O’Dwyer, John Peck, Luis Saenz, Ravi Vaidiswaran, Prasad Velaga, Raka Rao, Sandur Subramanyam, Mark Warren

Sourced through LinkedIn

 The following is a digest of my own answers, collated before they vanish in the replies-of-replies bowels of LinkedIn.

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By Michel Baudin • Blog clippings 0 • Tags: Assembly Lines, Fabrication, Flow, Job-shop, Machine Shops, Runners-Repeaters-Strangers

Nov 7 2017

More Sophisticated Graphics In Today’s New York Times

Mass shootings versus number of guns by country
Mass shootings versus guns per capita by country

“When the world looks at the United States, it sees a land of exceptions […] But why, they ask, does it experience so many mass shootings?[…] Perhaps, some speculate, it is because American society is unusually violent. Or its racial divisions have frayed the bonds of society. Or its citizens lack proper mental care under a health care system that draws frequent derision abroad. These explanations share one thing in common: Though seemingly sensible, all have been debunked by research on shootings elsewhere in the world. Instead, an ever-growing body of research consistently reaches the same conclusion. The only variable that can explain the high rate of mass shootings in America is its astronomical number of guns.”

The source for both charts is Adam Lankford from the University of Alabama. The charts Include countries with more than 10 million people and at least one mass public shooting with four or more victims.

Sourced from The New York Times

Michel Baudin‘s comments: Six months ago, I was bemoaning the absence of scatterplots in business analytics and more recently complimenting the New York Times for the sophistication of its graphics. Manufacturing professionals should not be shy about using scatterplots, as they have learned to do in Middle School. Here, they are used to highlight outliers, which isn’t the most common application. What this article — and these charts — show is how the tool can be used not just to solve technical problems but to inform a political debate as well.-

#Scatterplot

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By Michel Baudin • Press clippings 0 • Tags: scatterplot

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