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May 28 2015

Why Your Lean and Six Sigma Improvement Efforts Aren’t Driving Better Results | IndustryWeek | John Dyer

“Don’t expect a positive ROI from your lean and Six Sigma investments if they are nothing but a pretty picture.

I once had a plant manager tell me his factory had implemented Six Sigma, but there was not a single statistical process control chart.  How is that possible? Another had the control charts in place but refused to allow the operator to shut the process down when it indicated an out-of-control condition.  Another plant claimed it was lean but had a dozen bins of parts stacked on the floor as part of a two bin system.  Another plant routinely violated the daily production plan by rescheduling orders, and then the plant blamed the supply chain for causing it to frequently run out of parts (which then drove it to change the schedule… a vicious circle).”

Source: www.industryweek.com

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By Michel Baudin • Press clippings 8 • Tags: Fake Lean, LAME, Lean, Lean-Lite, Six Sigma, SPC

May 22 2015

The World Class Manufacturing programme at Chrysler, Fiat & Co. |Torbjørn Netland

“The company-specific production system (XPS) of Chrysler is the World Class Manufacturing (WCM) concept, developed by the Fiat Group in 2006. But, what exactly is the WCM? And, what does Chrysler see as keys to success in WCM?

A few answers are given these days at the 4th annual Lean Management Journal Conference in Birmingham, UK: in his morning keynote, Mauro Pino—Vice President for vehicle assembly operations and the Head of World Class Manufacturing in the Chrysler Group—explains how Chrysler “achieves manufacturing excellence across the globe”. Pino stresses that “WCM is how we do our business. Period.” The presentation reminds me of the WCM factories I visited in Brazil, Spain and Sweden last year, all of which confirmed that WCM can be a powerful improvement system—if implemented seriously. Let’s take a closer look at the concept of WCM.”

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By Michel Baudin • Blog clippings 1 • Tags: Company Production Systems, Fiat, WCM, Word-Class Manufacturing

May 14 2015

Where Have The Scatterplots Gone?

What passes for “business analytics” (BI), as advertised by software vendors, is limited to basic and poorly designed charts that fail to show interactions between variables, even though the use of scatterplots and elementary regression is taught to American middle schoolers and to shop floor operators participating in quality circles.

But the software suppliers seem to think that it is beyond the cognitive ability of executives. Technically, scatterplots are not difficult to generate, and there are even techniques to visualize more complex interactions than between pairs of variables, like trendalyzers or 3D scatterplots. And, of course, visualization is only the first step. You usually need other techniques to base any decision on data.

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By Michel Baudin • Data science 4 • Tags: data science, Quality, scatterplot, statistics

May 9 2015

Leather Accessory Manufacturing in India | YourStory.com | C. Ramalingegowda

 

Manufacturing
Packaging

“Torero is an Indian leather manufacturing company that is the exclusive global license holder for Cross brand. Here is their story. It  aligns with Prime Minister Narendra Modi’s ‘Make In India’ campaign. It has nearly $20 million in annual revenues, employs 4000 workers….”

Source: yourstory.com

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By Michel Baudin • Press clippings 0 • Tags: India, India Manufacturing, Manufacturing, Sweatshop

May 4 2015

Beyond A3s: Options for Shopfloor and Management Communication

A3s are still being touted as nothing short of a management revolution, but few organizations actually use them for operator work instructions, problem-solving, or hoshin planning. This raises the question of whether the objectives pursued with a paper format may not be easier to achieve with more recent technology. In this post, we consider options for operator work instructions. The other applications of A3s deserve separate treatment.

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By Michel Baudin • Management 3 • Tags: A3, Infographics, Master Data Management, Standard Work, Work instructions

Apr 24 2015

What Is The Metric For People Development? There Isn’t One

Contrary to popular opinion, it is not true that only what gets measured gets done. If it were, business, government, and society at large would come to a halt due to the damage done by metrics gamers, and for the lack of the contributions made by people who do not care whether they are measured. Deming is often quoted on this subject, as saying:

  • “It is wrong to suppose that if you can’t measure it, you can’t manage it – a costly myth.” (Deming, The New Economics. p.35)
  • “People with targets and jobs dependent upon meeting them will probably meet the targets – even if they have to destroy the enterprise to do it.” It is cited on Brainy Quotes, but without a source, and it may be apocryphal.

As he showed in his “red bead experiments,” his primary concern was about people being rewarded or punished based on random fluctuations in metrics that have nothing to do with their talents or efforts, but there are even more fundamental challenges in an area like people development.

You can measure how much dirt you have shoveled by weighing it, but developing people is different. There is not even a single direction. Some individuals are “hedgehogs,” who know one big thing like heat treatment, while others are “foxes,” who know many things like all the technical and human moving parts of a production line.

There is no metric– or even set of metrics — that can reasonably summarize people development, but it is nonetheless tangible and observable.

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By Michel Baudin • Management 6 • Tags: People development, Respect for Humanity, Respect for People, Training

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