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Why is it not enough to manufacture only as per specification?
This is a very famous case study of Ford transmission system vs Japanese transmission system. Both were manufactured as per drawing. But the difference was in the consistency. Japanese parts consistency was much higher. They were not just matching drawing specifications. But were very close to each other. Which means [...]
Fundamental Mistakes in 5S: Part 5
5. No FPP (Fixed Point Photography) “You have to know the past to know the future – Carl Sagan” Taking before picture of your 5S activity is like keeping history of what was happening. Before you jump to 1S, 2S, 3S…… wait. Take time and capture current state in photographs. [...]
Fundamental Mistakes in 5S: Part 4
4. Not keeping log of Red Tag items “You can’t manage what you don’t track – Valentino Crawford” In a large government utility once after doing a massive 5S campaign and removing a lot of items in 1s (Red Tag), the top management was reviewing the status. Suddenly a senior [...]
Fundamental Mistakes in 5S: Part 3
3. Not deciding time for action on Red Tag “Removing a Red Tag is more important than putting a Red Tag.” Usually the top management that starts 5S activity is not aware that the during the 1s (Seiri) activity, they would have to take timely decision on many items (especially [...]
Fundamental Mistakes in 5S: Part 2
2. Not putting Red Tag and doing 1S activity. “It is like entering a hall without a ticket.” Many times organizations are in hurry to do 5S (I don’t know why?). So they just identify iterms that are not required in a perticular area and put it in Red Zone [...]
Fundamental Mistakes in 5S – Part 1
1. Not doing why-why analysis after 1S activity “Putting “Red Tag” and keeping the items in Red Zone is not enough” In a large machine manufacturing company when we did Red Tag campaign, we found more than 2178 tags. But we just did not stop at putting those Red Tag [...]
The Ambulance Syndrome in Problem Solving
Ambulances are doing great service to the humanity by saving lives of millions around the world in case of emergency. There was a pit adjacent to a busy road, A person unwawre about it, accidently fell into it. A group of pedestrians walking by helped him. Someone pulled him out [...]
3 Fundamentals of Problem Solving
1. Brainstorming vs Blame-Storming. The most important thing in problem solving is that, there is no Finger Pointing. We have to fix Process not People. As Dr. Deming said 85% problems requires action on system / process. In my study tour to Japan I learned to ask “Why” rather than [...]