iSixSigma

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Kosta Chingas

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The Ultimate Organization?

I’m going to go out on a limb and open up a discussion on the “Ultimate Organization” here. In my last two posts, I talked a little bit about integrating the 6S culture in an organization (vs keeping it at a specialist level only) and organizational fear. I figured a logical progression of the overall…

Culture Change and Fear

There’s no doubt that fear can prevent an organization to be what it could be, but what can be done about it…how many times have you been in a situation where there were problems to solve, but no one stepped up to the plate to solve them because of fear? Piggy-backing on my previous posting,…

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Why is Quality Planning So Much of an Afterthought?

It’s really interesting for me to look back and think about how many times quality planning has come up as an afterthought. It is staggering for me to think about what could have happened if quality planning was done the proper way. Here’s an example….one time I was involved with a new product introduction, and…

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Practical Use of Control Plans

Now more than ever, the development and use of control plans play a critical role in succesfully implementing a new process. In my past, I have seen varying ways that control plans have been implemented, but I still struggle a little when I try to find a really good example of control plan development. To…

Leadership – Important Now More Than Ever

Recently James Considine and Stephen Crate have posted about management styles….and their posts have really made me think about management and leadership in general, especially during these challenging times… From my perspective, you have to lead people to achieve results. If you are a manager, indeed your job is to manage the business, but to…

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Innovation Gone Bad – Here We Go Again

Over the weekend, I happened to stumble upon this news link on Yahoo. The L.A. Times apparently published a front page advertisement that looked very much like a regular news ad. Of course upon inspection, the advertisement disclaimer was there. According to AFP: “Publisher Eddy Hartenstein told the Times he had decided to run the ad…

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Does It Get Easier As You Get Better? It Shouldn’t

Throughout my career I’ve had the pleasure of meeting colleagues from a very large variety of manufacturing cultures. Sometimes I talk to people that work in a “mass” environment with poor performance, and I hear about how good it must be to work in an efficient workplace, with relatively good performance. I always get the…

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Let Them Be Lean! – Um, What Does Lean Mean?

Over the years, I’ve come in contact with several different companies that say that they are “lean”. Yes, TPS (the Toyota Production System) is a great framework for production, with its teachings of one-piece flow, kanban, etc…but what about the actual implementation of the lean concepts at other companies besides Toyota? I’ve seen desks with…

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Can We Use Six Sigma Tools Outside of Projects?

One of the things that I see as a challenge to companies that grapple with a Six Sigma implementation is effective use of tools in “live” situations. By “live”, I mean in a normal operations context, not in a project context. When looking at the use of Six Sigma tools, using them in a project…

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The 1.5 Shift – Time For A Paradigm Shift?

Years ago (almost ten now!) when I was going through Black Belt training, I remember seeing the famous slide describing what a three-sigma world would look like. The presentation slide described how three-sigma aircraft landing performance would mean two long or short landings per day, and that 20,000 articles of mail would be lost per day at…

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Heres to a Great 2007!

(Continued from “Lean Journeys – Part 2“) Another year is upon us, and it’s time to look forward to new challenges and frontiers. It has been a while, and I will finally finish my thought on going lean from back in October! (Thanks for bearing with me – please refer back to “Lean Journeys –…

Lean Journeys – Part 2

(Continued from “Lean Journeys – Part 1“) There were two departments in the plant, and the press area served both with most of their raw material. After about two weeks on the job, I found that my area was shutting down one assembly cell per day on average. As you could imagine, my stress level…

Lean Journeys – Part 1

Deciding to go lean is very popular in today’s business climate. Eliminating overproduction and reducing excessive inventory (along with waste) is a must. If you’re a black-belt, you’re role may be central to the lean transformation (depending on the organization). Although there are many benefits to leaning-out operations, especially in a batch processing operation, there are…

Data Collection in the Factory

One of the toughest challenges that a manufacturing black-belt faces is institutionalizing data collection systems that yield project-critical information. Whether the needed data is attribute or variable, it is still a tough challenge to implement the system.Once the GR&R issues are resolved, it doesn’t get any easier. At this point, the black-belt has to make…

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Bringing Engineers Together

To a black-belt, looking at problems from a SIPOC point of view comes naturally… creating process flow maps, identifying potential inputs, identifying internal and external customers, etc. These activities are (or should be) core to implementing a given black-belt project. To an engineer that has not been though six-sigma training, many times these processes are…