Michael Clayton


  • Great discussion and important topic. But I agree with using MANY graphical tools for EXPLORATORY DATA ANALYSIS then show the graphs to domain knowlege folks for “ah-hah” reactions. Time series graphs are fine but its the CONTEXT data that is critical.
    Example: which TYPE of crime has most variance? Most far outliers? Does database have other…[Read more]

  • Thanks. Better every year. Have been applying LSS and TEAM PROBLEM SOLVING et al since 1993 but used DOE and SPC and EDA since 1960. Your group helps high or low tech factories as well as the office businesses. […]

  • Costs matter. Do you really know the value of less uncertainty to the product cost or reliability?
    Does the product have later-stage-of-completion screening test that would protect customers from maverick parts […]

  • All statistical methods are VERY sensitive to sample size to the point where MOST hypothesis tests will reject the null if the sample size is large. That has nothing to do with the ECONOMIC difference between […]

  • Eric Maass states the recent trends and next steps very well, in my opinion.

    Preventive measures were much harder when Six Sigma evolved in 1990’s, but as simulation and design tools grew along with cheaper, […]

  • Rather than demanding stability as pre-condition to using chart data, we have for many years at many companies used an Instability Index, simply the % of OOC points (by rule) simply to prioritize chart review […]

  • @Darth: Sorry if my tardiness offends you.
    I only view this site a few times a year, since manufacturing discussions seem to be few, and since they are kept online for long times, they can be useful to those with similar problems…IF the responses stay one the subject. So since this one went way off topic in typical social-media-type rants, I…[Read more]

  • @javiermora85 MBBinWI has good idea as does prior comment.

    So please think about, what is cost of product roughly, volume, and cost of field problems historically that might have suggested tracking. That would tell you if you can afford laser marking after polishing IF each casting is TRACKED in a DB to that point so you really know the input…[Read more]

  • Thanks for explaining the flattening process, nominal is not nominal, but rather the starting diameter roughly) which gets flattened to slightly larger diameter, so so you simply want to trend the data and set up SPC charts using a sampling plan based on your preliminary study data, right? I think if you had explained that in first post, DARTH…[Read more]

  • Connecting machines or gages to a DB should be simpler now days, since few tools are built without some kind of data port, that supports some kind of data transfer protocol. In the bad old days, we had to “wire behind the light bulbs” to see when a machine was ON vs OFF, but even that paid off over time with many tools.

    Tool data integration…[Read more]

  • Realizing that factory floor teams, middle management, finance, and upper management all need to think about the problems, various kinds of Process or Flow Maps have been used (often seems like style over substance, but if done simply for intended audience mix, can help get improvements funded. In my opinion, process and flow maps are less…[Read more]

  • IMO no one should be using R-bar/d2 these days.
    And if they do, think about what the subgrouping assumptions really are.
    d2 for sample size of 2 is near 1, while for 9 is near 3.
    But what if those samples are […]

  • When Motorola first developed the key steps to its 6 sigma efforts, the current DMAIC was just MAIC and step one was Measurement…which included MSA as well as gage and process tool characterization to prepare […]

  • The article encourages real-time feedback in manufacturing. Clearly that varies greatly from industry to industry. But the author’s bottom line statement is valid…and can be expensive to realize in complex […]

  • While TOC Jonah’s use many types of advanced logic diagrams (hundreds of different ones it seems) it is a logical approach to Pareto of major roadblocks to faster (lean) cycle time, one roadblock at a time, while […]

  • The individual has to decide whether they have time and talent to go deeper vs broader vs both.
    Within some industries, there is already major training efforts on Lean followed by Basic Statistics and then […]

  • Excellent overview that many books miss.
    From my experience, I noted these bases covered nicely in this article:
    1. “…regular, ad hoc and resource members”… imo Kaizen teams are ad hoc generally
    2. […]

  • Oldie but goodie!
    One of the best examples in my experience of using measurements for motivation to change came from using Dorian Shainin’s Multi-Vari plots….on big paper on wall on shop floor..where operators […]

  • for free software

    This type of visualization may require large viewing screen rather that tablet or PC monitor in my opinion, except for simplest causal loop diagrams or […]

  • Thanks.
    That table 1 was useful reminder for the DEFINE phase of DMAIC projects or Agile projects.

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