The Problem Barrier Assessment Sheet is used to isolate the obstacles to effective problem solving in your company. When you recognize a problem, note it on the sheet, and then investigate why the problem has persisted. Most problems did not just jump up recently. They have been around for a Read more…
The Pareto principle is the result of the work of the 19th Century economist, Vilfredo Pareto. He realized that wealth in Italy was distributed unevenly, and mathematically proved his observation. Today, the Pareto principle is more commonly known as the 80-20 rule. Simply put, 80 percent of problems are the Read more…
Having the support of your team is critical to the development of your continuous improvement culture. In most cases, that support, or lack of support is very obvious. When a person is on-board with a change, even if they are not a cheerleader for it, they tend to be open Read more…
A production playbook is basically a set of alternative options depending upon predictable situations. The most common playbook entries cover operating in unusual staffing or demand situations. One set of plays might clarify what is done when 1, 2, or 3 people are absent, and another set of plays might Read more…
Producer’s risk is the chance that a good product or batch will be rejected by an inspection. It is also known as Type I error, or alpha error. It is the probability that a batch with quality that exceeds your designated acceptable quality level will actually be rejected. In technical Read more…
Predictive maintenance is the practice of using data to try to anticipate and avoid machine failures. It differs from preventative maintenance in that it uses checks to identify abnormal conditions before the machine has a problem. Most failures in machines are not immediate, catastrophic failures. Electric motors might show changes Read more…
Preventive maintenance is the set of steps taken to avoid breakdowns in machines. These steps may include minor activities such as topping off fluids, inspection, lubrication, filter changes, and tightening as needed. It may also include more significant actions such as overhauls, rebuilds, and component replacement. In between those extremes Read more…
Metrics come in two basic flavors. One option is to measure the results of a process. This confirms that you did the right things and that you are on track. The problem, though, is that results metrics are lagging indicators. The activities that led to these results happened in the Read more…
For the purposes of continuous improvement, a product family is a group of products that follows a similar series of process steps. The value in this type of organization is that it supports flow. Similar products can be combined onto a mixed model production line. Generally speaking, the higher the Read more…
PDSA stands for Plan-Do-Study-Act, or less commonly, Plan-Do-Study-Adjust. It is a structured, iterative problem-solving approach popularized by W. Edwards Deming, who originally was mentored on the process by Walter Shewhart. With that origin in mind, it should come as no surprise that this method is also known as the Deming Read more…
A Pareto chart is a valuable prioritization and communication tool. It is simply an ordered bar chart showing the most common item on the left and the least common on the right. This tool capitalizes on the 80/20 rule. In effect, this rule says that 80% of whatever it is Read more…
A priority matrix is a decision-making tool that helps, as the name implies, with prioritization. A common matrix will include the importance of an action (or problem) and the urgency of it. The goal is to work on the tasks that will deliver the biggest bang for the buck first. Read more…