Blog posts on quality toolsPosts selected fromManagement Blog - Engineering Blog - Investing Blog and other blogs - Quality and Costs
Deming explained that increasing quality decreases costs. Page 3 of Out of the Crisis: Improve Quality –> Costs decrease because of less rework, fewer mistakes, fewer delays…
Like most models this does not explain everything. Achieving some quality desires does cost more. And the article examines how to look at the issue of cost reduction in health care, where the view that higher quality costs more persists to a larger extent than elsewhere. There is significant room in health care for adopting improvement that will improve quality and reduce costs because the systems are so poorly designed they are both increasing costs and decreasing quality over what could be achieved. continue reading: Quality and Costs - Six Sigma and Process Drift
- Better and Different
The answer, as I see it, is to be better and different (when necessary).
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if you have to choose one, just being better will work most of the time. The problem is (using an example from Deming, page 9 New Economics) when, for example, carburetors are eliminated by innovation (fuel injectors) no matter how well you make them you are out of business.
Often people mistake Deming’s ideas as only about being better. He stressed not only continual improvement (Kaizen, incremental improvement, SPC) but also innovation. He stressed innovation both in the normal sense of innovating new products for customers and also innovation in managing the organization. continue reading: Better and Different - Lean Beyond the Factory Floor
Experts (in TQM, Deming’s idea’s, Six Sigma, BPR, Lean…) always stress the importance of involving not just others (when talking to management) but their (managers) work too. But fairly consistently management adopts improvement ideas mostly for others, not for their own work. As organizations apply management improvement ideas on some portion of the work the talk of going beyond “factory floor” improvements becomes more common as improvements are seen where it is applied.
Fast Cycle Change in Knowledge-Based Organizations by Ian Hau and Ford Calhoun, Jun 1997 is a good example of lean thinking, eliminating waste… outside the factory floor. continue reading: Lean Beyond the Factory Floor - Brainstorming Under Attack
Brainstorming is about creating an opportunity to bring new ideas the forefront.
There are other useful tools such as the affinity diagram which can serve as another option (or can serve as a tool to work with the results of brainstorming).
And Edward DeBono has excellent creativity tools, like his 6 thinking hats. Brainstorming is a useful tool when applied properly but it is only one tool and other tools should be used also. continue reading: Brainstorming Under Attack - Brainstorming Under Attack
Brainstorming is about creating an opportunity to bring new ideas the forefront.
There are other useful tools such as the affinity diagram which can serve as another option (or can serve as a tool to work with the results of brainstorming).
And Edward DeBono has excellent creativity tools, like his 6 thinking hats. Brainstorming is a useful tool when applied properly but it is only one tool and other tools should be used also. continue reading: Brainstorming Under Attack - Toyota IT for Kaizen
IT often does the opposite of lean management and makes things more complex, more prone to error, less effective, etc.. Often all in search of only one thing – cutting costs. For that people should not be faulted for being skeptical of IT solutions. However, that does not mean that IT cannot play a part in improvements. It can, just be careful.
I find it a good sign when the CIO office is helping people find solutions at the request of the users rather than dictating solutions from on high. Some of the dictating might be necessary to optimize the system of IT (some local sub optimization may be required for the overall good) but in my opinion this is used as an excuse far too often.
Related: The Edge-case Excuse (a post I wrote more recently on the topic of error prone IT solutions) continue reading: Toyota IT for Kaizen - CEO Flight Attendant
This getting out and seeing work in action is exposed a great deal, including a lean management concept, Genchi Genbutsu – to go to see the problem in situ (not just reading a report about it).
The success of many management practices is more a matter of how the practice is done than if it is done. Also the success depends on the rest of the management system. Practices cannot just be copied. But you can learn from what others find useful and figure out how that idea would work within your organization. continue reading: CEO Flight Attendant - TQM for the Water Business
Deming did not like the term TQM. It was not defined, so each person using it meant something different. And the faddish nature of the term drew a large number of “hacks” (consultants who spoke with authority but without knowledge). Seeing the term TQM used now [2006] however, I find refreshing. To use the term TQM you must go against the temptation to talk only about the current fad (learning organizations, reengineering, balanced scorecard, six sigma, lean…). This author defines what he means by TQM... continue reading: TQM for the Water Business - The Exciting Life of Industrial Statisticians
All of this provides great new opportunities for industrial statisticians to serve as statistical leaders-a term popularized by the late and great Ed Deming (see Hahn and Hoerl, 1998). Statistical leaders engage principally in leveraging statistical concepts and thinking (see Hoerl, Hooper, Jacobs and Lucas , 1993), and focus their activities on mentoring and supporting the most business-vital and technically challenging problems dealing with getting the right data, and converting such data into actionable information.
continue reading: The Exciting Life of Industrial Statisticians - Distorting the System or the Data is Easier Than Improving the System
3 ways to improve the figures: distort the data, distort the system and improve the system. Improving the system is the most difficult.
When people mistake the data proxy for the thing to improve they focus on improvement of how the data looks not of the system. That is the wrong strategy. The correct strategy is to focus on improving the system and as a way of verifying results you then look at measures. But you must always remember those measures are not the end they are an attempt to measure the end you are trying to achieve. continue reading: Distorting the System or the Data is Easier Than Improving the System - Lean is Harmony
The tools are useful, but they are not the end. Just using the tools can help move an organization to the point where they are ready to truly examine how to improve. Most often the attempts (just like previous attempts with quality management, six sigma… did) stop short of more than superficial change where a few new tools are used in the same old system. continue reading: Lean is Harmony - Lean is Harmony
The tools are useful, but they are not the end. Just using the tools can help move an organization to the point where they are ready to truly examine how to improve. Most often the attempts (just like previous attempts with quality management, six sigma… did) stop short of more than superficial change where a few new tools are used in the same old system. continue reading: Lean is Harmony - Turning The PDSA Cycle Rapidly (Iteration)
One point he made was that he often finds that organizations fail to properly “turn” the PDSA cycle (by running through it 5-15 times quickly and instead to one huge run through the PDSA cycle). One slow turn is much less effective then using it as intended to quickly test and adapt and test and adapt…
In my experience people have difficulty articulating a theory to test (which limits the learning that can be gained). He offered a strategy to help with this: write down the key outcome that is desired. Then list the main drivers that impact that outcome. Then list design changes for each outcome to be tested with the PDSA cycle. continue reading: Turning The PDSA Cycle Rapidly (Iteration) - Common Cause Variation
Every system has variation. Common cause variation is the variation due to the current system. Dr. Deming increased his estimate of variation due to the system (common cause variation) to 97% (earlier in his life he cited figures around 80%). Special cause variation is that due to some special (not part of the system) cause.
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To take action against a special cause, that isolated special cause can be examined. Unfortunately that approach (the one we tend to use almost all the time) is the wrong approach for systemic problems (which Deming estimated at 97% of the problems).
That doesn’t mean it is not possible to improve results by treating all problems as some special event. Examining each failure in isolation is just is not as effective. Instead examine the system that produced those results is the best method. continue reading: Common Cause Variation
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