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Sep 19 2014

The Creative Benefits of Boredom | HBR Blog Network | David Burkus

“[…]a certain level of boredom might actually enhance the creative quality of our work […]”

Source: blogs.hbr.org

Michel Baudin‘s comments:

It is one step away from claiming that boredom makes you creative, which would make no sense. The frustration of boredom may motivate you to use your creativity, but deliberately boring people in order to make them creative is not something I would recommend.

I think that creativity is innate, but much more widely spread than most managers and engineers believe. The example in the article is about sales;  I am more familiar with manufacturing, where most jobs are repetitive, tedious, and boring.

They jobs are also tiring, but most production operators will tell you that they don’t mind the tiredness as much as the slowness of the clock. Boredom is their number one enemy, and participation in improvement activities a welcome relief from it, as well as an opportunity to be creative.

People who are bored by repetitive tasks go “on automatic.” Their hands keeps executing the sequence of tasks with accuracy and precision, while their minds wander off to, perhaps, the lake they fish in on week-ends. While on automatic, you don’t think about improvements.

Changes in the routine, whether deliberate or accidental, refocus their minds on the workplace. This includes product changes, spec changes, rotation between work stations, or any breakdown like defects in the product, component shortages, or machine stoppages. During theses changes, while engaged, your mind is focused on responding as you were trained to, and avoiding mistakes. If you think of better ways to do this work, they go on the back burner in your mind, while you attend to immediate needs.

Depending on the management culture, operators may or may not be willing to share these ideas. They may be afraid of humiliation by a tactless manager, or they may fear that improving their job puts it in jeopardy,…

To put to use the operators’ creativity, you have to organize for this purpose, and it can’t be while the line is running. This is why continuous improvement requires structures, procedures, and leadership.

See on Scoop.it – lean manufacturing

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By Michel Baudin • Blog clippings • 0 • Tags: boredom, Continuous improvement, creativity

Sep 7 2014

VSM Pitfall: unnecessary process | Chris Hohmann

Value Stream Mapping (VSM) is probably the main analysis tool and the most used in the lean toolbox. Easy to understand and handle, VSM is the starting point of improvement workshops and kaizen eve…

Source: hohmannchris.wordpress.com

Michel Baudin‘s comments:

Thoughtful comments, as usual from Chris Hohmann.

However, we need to go further and question the wisdom of reducing Lean implementation to Value-Stream Mapping and kaizen events when neither tool is central to the Toyota Production System.

“Value-Stream Mapping,” which is really materials and information flow mapping, is a minor tool at Toyota, used only with suppliers who have delivery problems. And “kaizen events” don’t exist at Toyota.

See on Scoop.it – lean manufacturing

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By Michel Baudin • Blog clippings • 1 • Tags: Kaizen Events, Lean, Lean implementation, Toyota, VSM

Sep 2 2014

Are Part Numbers Too Smart for Their Own Good? | ENGINEERING.com

[…] technology experts are warning that the use of such descriptive part numbers is not necessarily so “smart,” and that they could drag down productivity in today’s fast-changing manufacturing environments. A smarter tactic, they assert, is to employ auto-generated “insignificant” or “non-intelligent” part numbers and let information about the part reside in a database. […]

Source: www.engineering.com

See on Scoop.it – lean manufacturing

Michel Baudin‘s comments:
For details on the reasons to get rid of so-called “smart” part numbers, see  Why “Smart” part numbers should be replaced with keys and property lists.

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By Michel Baudin • Press clippings • 0 • Tags: Master Data, nomenclature, smart part numbers, Technical Data Management

Gauss with bell shape banknote

Aug 23 2014

The bell curve: “Normal” or “Gaussian”?

Most discussions of statistical quality refer to the “Normal distribution,” but “Normal” is a loaded word. If we talk about the “Normal distribution,” it implies that all other distributions are, in some way, abnormal. The “Normal distribution” is also called “Gaussian,” after the discoverer of many of its properties, and I prefer it as a more neutral term. Before Germany adopted the Euro, its last 10-Mark note featured the bell curve next to Gauss’s face.

The Gaussian distribution is widely used, and abused, because its math is simple, well known, and wonderful. Here are a few of its remarkable properties:

  1. It applies to a broad class of measurement errors. John Herschel arrived at the Gaussian distribution for measurement errors in the position of bodies in the sky simply from the fact that the errors in x and y should be independent and that the probability of a given error should depend only on the distance from the true point.
  2. It is stable. If you add Gaussian variables, or take any linear combination of them, the result is also Gaussian.
  3. Many sums of variables converge to it.  The Central Limit Theorem (CLT) says that, if you add variables that are independent, identically distributed, with a distribution that has a mean and a standard deviation, they sum converges towards a Gaussian. It makes it an attractive model, for example, for order quantities for a product coming independently from a large number of customers.
  4. Mint syrup diffusion in water
    Mint syrup diffusion in water

    It solves the equation of diffusion. The concentration of, say, a dye introduced into clear water through a pinpoint is a Gaussian that spreads overt time. You can experience it in your kitchen: fill a white plate with about 1/8 in of water, and drop the smallest amount of mint syrup you can in the center. After a few seconds, the syrup in the water forms a cloud that looks very much like a two-dimensional Gaussian bell shape for concentration, as shown on the right. And it fact it is, because the Gaussian density function solves the diffusion equation, with a standard deviation that rises with time. It also happens in gases, but too quickly to observe in your kitchen, and in solids, but too slowly.

  5. It solves the equation of heat transfer by conduction. Likewise, when heat spreads by conduction from a point source in a solid, the temperature profile is Gaussian… The equation is the same as for diffusion.
  6. Unique filter. A time-series of raw data — for temperatures, order quantities, stock prices,… — usually has fluctuations that you want to smooth out in order to bring to light the trends or cycles your are looking for. A common way of doing this is replacing each point with a moving average of its neighbors, taken over windows of varying lengths, often with weights that decrease with distance, so that a point that is 30 minutes in the past counts for less than the point of 1 second ago. And you would like to set these weights so that, whenever you enlarge the window, the peaks in your signal are eroded and the valleys fill up. A surprising, and recent discovery (1986) is that the only weighting function that does this is the Gaussian bell curve, with its standard deviation as the scale parameter.
  7. Own transform. This is mostly of interest to mathematicians, but the Gaussian bell curve is its own Laplace transform, which drastically simplifies calculations.
  8. …

For all these reasons, the Gaussian distribution deserves attention, but it doesn’t mean that there aren’t other models that do too. For example, when you pool the output of independent series of events, like failures of different types on a machine, you tend towards a Poisson process, characterized by independent numbers of events in disjoint time intervals, and a constant occurrence rate over time. It is also quite useful but it doesn’t command the same level of attention as the gaussian.

The most egregious misuse of the gaussian distribution is in the rank-and-yank approach to human resources, which forces bosses to rate their subordinates “on a curve.” Measuring several dimensions of people performance and examining their distributions might make sense, but mandating that grades be “normally distributed” is absurd.

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By Michel Baudin • Data science • 1 • Tags: gauss, gaussian, measurement, measurement error, Normal distribution, scale-space filtering

Aug 21 2014

Purpose and Etiquette of On-Line Discussions

In the Lean Six Sigma Worldwide discussion group on LinkedIn, Steven Borris asked about the purpose of on-line discussions, whether they should stick precisely to the topic they were started on, and how disagreements between participants should be expressed or handled. As a participant in a variety of professional forums for the past 16 years, I have come to think of an online discussion as a conference that is always in session, in which the posting etiquette should be the same as at conferences.

Contributors should think of readers first. LinkedIn members read discussions for enlightenment, not entertainment. This isn’t Facebook. When readers browse a discussion, it is based on its subject, and that is what they expect to be covered. Like the title of a book, the name of a discussion announces what it is about. Readers are drawn to it by the need for information on that topic and have a legitimate expectation that the posts will be about it. If participants disappoint them, they go away upset at having been misled. For this reason,  discussions should stick to their subject, and group moderators or managers should make sure they do, with interesting digressions spawning new discussions.

Professional readers are also turned off by personal attacks and posts that question other posters’ motives. The participants need to “play nice” with each other, but a discussion where they all express the exact same ideas would not be informative and would be dull. The contributors to the discussions I participate in often have decades of experience that have shaped their perspectives on the topics, differently based on the industries and companies they have worked for. They are not on the same wavelength.

Often, however, apparent disagreements disappear when the context is properly set. For example, in his 1999 book on Six Sigma,  Mikel Harry wrote that the future of all business depends on an understanding of statistics; Shigeo Shingo, on the other hand, had no use for this discipline and wrote in ZQC that it took him 26 years to become free of its spell.

That sounds like a clear-cut disagreement. Mikel Harry developed Six Sigma at Motorola in the 1980s; Shigeo Shingo was a consultant and trainer primarily in the Japanese auto industry from 1945 to the 1980s, too early for discussion groups. Harry and Shingo worked in different industries with different needs at different times.With proper context setting, they can be both right.  Posts that start with “In my experience…” and support topical conclusions with an account of what that experience go a long way towards setting that context.

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By Michel Baudin • Management • 3 • Tags: forums, LinkedIn, On-line discussions

Aug 18 2014

Toyota Cutting the Fabled Andon Cord, Symbol of Toyota Way | Automotive News

Toyota is retiring the fabled “andon cord,” the emergency cable strung above assembly lines that came to symbolize the built-in quality of the Toyota Way and was widely copied through the auto industry and beyond.

Source: www.autonews.com

 

Michel Baudin‘s comments:
The point of having a cord rather than buttons was that the cord could be pulled from anywhere along the line, whereas buttons require you to be where they are. It is the same reason many buses have cords for passengers to request stops rather than buttons.

Toyota’s rationale for moving to buttons, according to the article, is the desire to clear the overhead space. Another advantage, not stated in the article, is that the alarm from a button is more location-specific than from a cord.

Another reason to use a cord was that you didn’t have to change it when you rearranged the line, whereas relocating buttons required rewiring. But the wireless button technology has made this a moot point.

See on Scoop.it – lean manufacturing

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By Michel Baudin • Press clippings • 1 • Tags: Andon, Andon cord, Assembly line design, Lean assembly, Toyota

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